Rotary-driven surgical stapling assembly comprising eccentrically driven firing member

ABSTRACT

A surgical stapling assembly is disclosed. The surgical stapling assembly can include a first jaw, a second jaw, an articulation joint, a closure drive comprising a first flexible rotary drive extending through the articulation joint, and a firing drive comprising a second flexible rotary drive extending through the articulation joint and rotatable independent of the first flexible rotary drive. The surgical stapling assembly can further include a 3D-printed component. The surgical stapling assembly can be configured to form different staple shapes, such as non-planar staples and planar staples, can include an eccentrically-driven firing assembly, and/or can include a floatable component. The surgical stapling assembly can include a staple cartridge including a longitudinal support beam.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments, endeffectors, and staple cartridges for use therewith that are designed tostaple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of a surgical stapling instrumentcomprising a handle, a shaft assembly, and an end effector, inaccordance with at least one aspect of the present disclosure.

FIG. 2 is a perspective view of the end effector and a portion of theshaft assembly of the surgical stapling instrument of FIG. 1, whereinthe end effector is illustrated in a straight, or non-articulated,configuration, in accordance with at least one aspect of the presentdisclosure.

FIG. 3 is a perspective view of the end effector and a portion of theshaft assembly of the surgical stapling instrument of FIG. 1, whereinthe end effector is illustrated in an articulated configuration, inaccordance with at least one aspect of the present disclosure.

FIG. 4 is an exploded perspective view of the end effector and a portionof the shaft assembly of the surgical stapling instrument of FIG. 1, inaccordance with at least one aspect of the present disclosure.

FIG. 5 is a cross-sectional elevation view of the end effector and aportion of the shaft assembly of the surgical stapling instrument ofFIG. 1, wherein the end effector is illustrated in an unfired, clampedconfiguration, in accordance with at least one aspect of the presentdisclosure.

FIG. 6 is a plan view of the end effector and a portion of the shaftassembly of the surgical stapling instrument of FIG. 1, in accordancewith at least one aspect of the present disclosure.

FIG. 7 is a cross-sectional elevation view of the end effector and aportion of the shaft assembly of FIG. 1 taken along section line 6-6 inFIG. 6, wherein the end effector is illustrated in an openconfiguration, in accordance with at least one aspect of the presentdisclosure.

FIG. 8 is a cross-sectional elevation view of the end effector and aportion of the shaft assembly of FIG. 1 taken along section line 7-7 inFIG. 6, wherein the end effector is illustrated in a clampedconfiguration, in accordance with at least one aspect of the presentdisclosure.

FIG. 9 is a perspective view of a surgical stapling assembly comprisinga shaft assembly and the end effector of FIG. 1, wherein the endeffector is attached to the shaft assembly by way of an articulationjoint, in accordance with at least one aspect of the present disclosure.

FIG. 10 is an exploded perspective view of the surgical staplingassembly of FIG. 9, in accordance with at least one aspect of thepresent disclosure.

FIG. 11 is a cross-sectional elevation view of the surgical staplingassembly of FIG. 9, wherein the end effector is illustrated in anunfired, clamped configuration, in accordance with at least one aspectof the present disclosure.

FIG. 12 is a perspective view of a surgical stapling assembly comprisinga shaft assembly and the end effector of FIG. 1, wherein the endeffector is attached to the shaft assembly by way of an articulationjoint, in accordance with at least one aspect of the present disclosure.

FIG. 13 is an exploded perspective view of the surgical staplingassembly of FIG. 12, in accordance with at least one aspect of thepresent disclosure.

FIG. 14 is a cross-sectional elevation view of the surgical staplingassembly of FIG. 12, wherein the end effector is illustrated in anunfired, clamped configuration, in accordance with at least one aspectof the present disclosure.

FIG. 15 is a perspective view of a surgical stapling assembly comprisinga shaft assembly and the end effector of FIG. 1, wherein the endeffector is attached to the shaft assembly by way of an articulationjoint, in accordance with at least one aspect of the present disclosure.

FIG. 16 is an exploded perspective view of the surgical staplingassembly of FIG. 15, in accordance with at least one aspect of thepresent disclosure.

FIG. 17 is a cross-sectional elevation view of the surgical staplingassembly of FIG. 15, wherein the end effector is illustrated in anunfired, clamped configuration, in accordance with at least one aspectof the present disclosure.

FIG. 18 is a perspective view of a surgical end effector assemblycomprising the end effector of FIG. 1 and a flexible firing drivesystem, in accordance with at least one aspect of the presentdisclosure.

FIG. 19 is an exploded perspective view of the surgical staplingassembly of FIG. 18, in accordance with at least one aspect of thepresent disclosure.

FIG. 20 is a cross-sectional elevation view of the surgical end effectorassembly of FIG. 18, wherein the surgical end effector assembly isillustrated in an unfired, clamped configuration, in accordance with atleast one aspect of the present disclosure.

FIG. 21 is a perspective view of robotic controller, in accordance withat least one aspect of the present disclosure.

FIG. 22 is a perspective view of a robotic arm cart for a roboticsurgical system, depicting manipulators on the robotic arm cart operablysupporting surgical tools, in accordance with at least one aspect of thepresent disclosure.

FIG. 23 is a side view of a manipulator of the surgical arm cart of FIG.22 and a surgical grasping tool, in accordance with at least one aspectof the present disclosure.

FIG. 24 is a perspective view of an end effector assembly comprising ananvil, a channel, and a staple cartridge, in accordance with at leastone aspect of the present disclosure.

FIG. 25 is a cross-sectional perspective view of the end effectorassembly of FIG. 24, in accordance with at least one aspect of thepresent disclosure.

FIG. 26 is a partial cross-sectional perspective view of the endeffector assembly of FIG. 24, wherein the end effector assemblycomprises a firing drive configured to deploy staples from the staplecartridge and a closure drive configured to open and close the anvilrelative to the channel, in accordance with at least one aspect of thepresent disclosure.

FIG. 27 is a cross-sectional elevation view of the end effector assemblyof FIG. 24, in accordance with at least one aspect of the presentdisclosure.

FIG. 28 is a partial cross-sectional perspective view of the endeffector assembly of FIG. 24, wherein the end effector assemblycomprises a firing assembly comprising an upper firing member and alower firing member, and wherein the upper firing member is illustrateddisengaged from the lower firing member, in accordance with at least oneaspect of the present disclosure.

FIG. 29 is an exploded perspective view of the staple cartridge and asupport beam of the end effector assembly of FIG. 24, in accordance withat least one aspect of the present disclosure.

FIG. 30 is a cross-sectional perspective view of the staple cartridgeand the support beam of the end effector assembly of FIG. 24, inaccordance with at least one aspect of the present disclosure.

FIG. 31 is a cross-sectional elevation view of the end effector assemblyof FIG. 24, in accordance with at least one aspect of the presentdisclosure.

FIG. 32 is a cross-sectional perspective view of a proximal end of theend effector assembly of FIG. 24 with various components not shown forclarity, in accordance with at least one aspect of the presentdisclosure.

FIG. 33 is a cross-sectional perspective view of a distal end of the endeffector assembly of FIG. 24, in accordance with at least one aspect ofthe present disclosure.

FIG. 34 is a perspective view of a support beam for use with a staplingassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 35 is an cross-sectional elevation view of the support beam of FIG.34 and a sled pinned to the support beam, in accordance with at leastone aspect of the present disclosure.

FIG. 36 is an exploded perspective view of a portions of a staplingassembly including a support beam, a firing member assembly, and a sled,in accordance with at least one aspect of the present disclosure.

FIG. 37 is an exploded perspective view of the portions of the staplingassembly of FIG. 33, wherein a distal end of the support beam is shownin hidden lines to show the profile of a longitudinal channel of thesupport beam, in accordance with at least one aspect of the presentdisclosure.

FIG. 38 is an elevation view of a support beam for use with a staplingassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 39 is an elevation view of a support beam for use with a staplingassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 40 is a cross-sectional elevation view of a stapling assemblycomprising a staple cartridge, a sled, a cartridge support, and anI-beam, in accordance with at least one aspect of the presentdisclosure.

FIG. 41 is an elevation view of the cartridge support of FIG. 40, inaccordance with at least one aspect of the present disclosure.

FIG. 42 is an elevation view of a cartridge support for use with asurgical stapling assembly, in accordance with at least one aspect ofthe present disclosure.

FIG. 43 is a cross-sectional elevation view of portions of a staplingassembly including a sled and a cartridge support, in accordance with atleast one aspect of the present disclosure.

FIG. 44 is an elevation view of a sled configured to fit within guideslots of a staple cartridge or cartridge support of a stapling assembly,in accordance with at least one aspect of the present disclosure.

FIG. 45 is a cross-sectional perspective view of a portion of acartridge support configured to receive a sled therein, in accordancewith at least one aspect of the present disclosure.

FIG. 46 is a schematic of portions of a stapling assembly including ananvil, a firing member, a cartridge jaw, and a sled pinned to the firingmember, in accordance with at least one aspect of the presentdisclosure.

FIG. 47 is a cross-sectional view of a stapling assembly comprising acartridge channel and an anvil, in accordance with at least one aspectof the present disclosure.

FIG. 48 is a perspective view of a firing member assembly comprising aprimary body portion and a drive nut, in accordance with at least oneaspect of the present disclosure.

FIG. 49 is an exploded perspective view of the firing member assembly ofFIG. 48, in accordance with at least one aspect of the presentdisclosure.

FIG. 50 is a perspective view of a firing member assembly comprising theprimary body portion of the firing member assembly of FIG. 48 and adrive nut, in accordance with at least one aspect of the presentdisclosure.

FIG. 51 is an exploded perspective view of the firing member assembly ofFIG. 50, in accordance with at least one aspect of the presentdisclosure.

FIG. 52 is a perspective view of the firing member assembly of FIG. 50,wherein the drive nut is welded to the primary body portion, inaccordance with at least one aspect of the present disclosure.

FIG. 53 is a partial cross-sectional, exploded perspective view of astapling assembly comprising a channel jaw, a drive screw, and a firingmember assembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 54 is an elevation view of the firing member assembly of FIG. 53,in accordance with at least one aspect of the present disclosure.

FIG. 55 is an exploded elevation view of the firing member assembly ofFIG. 53, in accordance with at least one aspect of the presentdisclosure.

FIG. 56 is a partial cross-sectional elevation view of the firing memberassembly of FIG. 53, in accordance with at least one aspect of thepresent disclosure.

FIG. 57 is a perspective view of a firing member assembly comprising aprimary body portion and a drive nut, in accordance with at least oneaspect of the present disclosure.

FIG. 58 is an elevation view of the firing member assembly of FIG. 57,in accordance with at least one aspect of the present disclosure.

FIG. 59 is a perspective view of the primary body portion of the firingmember assembly of FIG. 57, in accordance with at least one aspect ofthe present disclosure.

FIG. 60 is a cross-sectional elevation view of the firing memberassembly of FIG. 57, in accordance with at least one aspect of thepresent disclosure.

FIG. 61 is another cross-sectional elevation view of the firing memberassembly of FIG. 57 taken through distal apertures of the primary bodyportion, in accordance with at least one aspect of the presentdisclosure.

FIG. 62 is a perspective view of a firing member assembly comprising aprimary body portion and a drive nut assembly comprising an internaldrive nut and an external drive portion, in accordance with at least oneaspect of the present disclosure.

FIG. 63 is a perspective view of the firing member assembly of FIG. 62,wherein a portion of the external drive portion of the drive nut iscutaway for illustrative purposes to expose the internal drive nut, inaccordance with at least one aspect of the present disclosure.

FIG. 64 is a perspective view of the primary body portion and internaldrive nut of the firing member assembly of FIG. 62, in accordance withat least one aspect of the present disclosure.

FIG. 65 is an elevation view of the primary body portion and theinternal drive nut of the firing member assembly of FIG. 62, inaccordance with at least one aspect of the present disclosure.

FIG. 66 is a perspective view of the firing member assembly of FIG. 62,in accordance with at least one aspect of the present disclosure.

FIG. 67 is an elevation view of a firing member assembly comprising aprimary body portion and a drive nut, wherein the primary body portioncomprises a proximal tail extension, in accordance with at least oneaspect of the present disclosure.

FIG. 68 is a perspective view of a firing member assembly threadablycoupled with a firing drive screw, wherein the firing member assemblycomprises a primary body portion and a drive nut, in accordance with atleast one aspect of the present disclosure.

FIG. 69 is a partial cross-sectional elevation view of the firing memberassembly of FIG. 68, wherein the drive nut is cross-sectioned through avertical plane, in accordance with at least one aspect of the presentdisclosure.

FIG. 70 is a perspective view of the drive nut of the firing memberassembly of FIG. 68, in accordance with at least one aspect of thepresent disclosure.

FIG. 71 is a perspective, cross-sectional view of the firing memberassembly of FIG. 68, in accordance with at least one aspect of thepresent disclosure.

FIG. 72 is an elevation view of the firing member assembly of FIG. 68,in accordance with at least one aspect of the present disclosure.

FIG. 73 is an elevation view of a firing member assembly comprising aprimary body portion and a drive nut, in accordance with at least oneaspect of the present disclosure.

FIG. 74 is a cross-sectional perspective view of an end effectorassembly comprising a cartridge channel, a staple cartridge, an anvil,and a firing assembly, in accordance with at least one aspect of thepresent disclosure.

FIG. 75 is a cross-sectional elevation view of the end effector assemblyof FIG. 74 viewed from a proximal end of the end effector assembly, inaccordance with at least one aspect of the present disclosure.

FIG. 76 is a partial cross-sectional perspective view of the endeffector assembly of FIG. 74, wherein the firing member assemblycomprises a firing drive screw and a firing member assembly, inaccordance with at least one aspect of the present disclosure.

FIG. 77 is a partial cross-sectional perspective view of the channel andthe firing assembly of FIG. 74, wherein certain hidden features areshown with dashed lines for illustrative purposes, in accordance with atleast one aspect of the present disclosure.

FIG. 78 is a partial cross-sectional elevation view of the end effectorassembly of FIG. 74, in accordance with at least one aspect of thepresent disclosure.

FIG. 79 is a cross-sectional elevation view of a surgical staplingassembly comprising a channel, a staple cartridge, an anvil, and afiring assembly comprising a drive screw, a firing member assembly, anda sled, in accordance with at least one aspect of the presentdisclosure.

FIG. 80 is an elevation view of the firing member assembly of FIG. 79,in accordance with at least one aspect of the present disclosure.

FIG. 81 is a cross-sectional elevation view of a jaw assembly for usewith a surgical stapling assembly, wherein the jaw assembly comprises achannel and a firing drive screw, in accordance with at least one aspectof the present disclosure.

FIG. 82 is a perspective view of a surgical stapling assembly comprisinga staple cartridge, a cartridge channel, and a firing drive assembly,wherein the staple cartridge is hidden in FIG. 82, in accordance with atleast one aspect of the present disclosure.

FIG. 83 is a partial cross-sectional perspective view of the surgicalstapling assembly of FIG. 82, in accordance with at least one aspect ofthe present disclosure.

FIG. 84 is an elevation view of a portion of the cartridge channel andthe firing member assembly of FIG. 82, wherein a distal support head andpair of bushings are hidden in FIG. 84, in accordance with at least oneaspect of the present disclosure.

FIG. 85 is a perspective view of a surgical stapling assembly comprisinga cartridge channel and a firing member assembly supported by supportflanges of the cartridge channel, in accordance with at least one aspectof the present disclosure.

FIG. 86 is an elevation view of a portion of a surgical staplingassembly comprising a firing drive screw and a channel support, whereina proximal end of the firing drive screw is pivotally mounted at thecartridge support, in accordance with at least one aspect of the presentdisclosure.

FIG. 87 is an elevation view of the portion of the surgical staplingassembly of FIG. 86, wherein the firing drive screw is illustrated in aloaded configuration, in accordance with at least one aspect of thepresent disclosure.

FIG. 88 is an elevation view of a firing member assembly comprising aprimary body portion and a drive nut floatably mounted within theprimary body portion, in accordance with at least one aspect of thepresent disclosure.

FIG. 89 is an elevation view of the firing member assembly of FIG. 88pre-assembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 90 is an elevation view of the firing member assembly of FIG. 88mid-assembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 91 is an elevation view of the firing member assembly of FIG. 88partially assembled, in accordance with at least one aspect of thepresent disclosure.

FIG. 92 is an elevation view of a flexible firing drive screw comprisinga flexible core member and an outer helical member, in accordance withat least one aspect of the present disclosure.

FIG. 93 is a cross-sectional schematic of the flexible firing drivescrew of FIG. 92, in accordance with at least one aspect of the presentdisclosure.

FIG. 94 is a schematic representation of a firing assembly comprising aflexible firing drive screw, in accordance with at least one aspect ofthe present disclosure.

FIG. 95 is an elevation view of a portion of a firing drive screw foruse with a surgical stapling assembly, in accordance with at least oneaspect of the present disclosure.

FIG. 96 is an elevation view of a portion of a firing drive screw foruse with a surgical stapling assembly, wherein the firing drive screwcomprises an overmolded section of threads, in accordance with at leastone aspect of the present disclosure.

FIG. 97 is an elevation view of a portion of the firing drive screw ofFIG. 96, wherein the overmolded section of threads are removed forclarity, in accordance with at least one aspect of the presentdisclosure.

FIG. 98 is a perspective view of a shaft coupling for use with a drivesystem of a surgical stapling assembly, in accordance with at least oneaspect of the present disclosure.

FIG. 99 is a perspective view of a shaft coupling for use with a drivesystem of a surgical stapling assembly, in accordance with at least oneaspect of the present disclosure.

FIG. 100 is a perspective view of a shaft coupling for use with a drivesystem of a surgical stapling assembly, in accordance with at least oneaspect of the present disclosure.

FIG. 101 is a perspective view of a closure drive assembly comprising aclosure drive screw and a closure wedge configured to open and close ajaw of an end effector assembly, in accordance with at least one aspectof the present disclosure.

FIG. 102 is an elevation view of the closure drive assembly of FIG. 101and an anvil, in accordance with at least one aspect of the presentdisclosure.

FIG. 103 is a cross-sectional elevation view of the closure driveassembly of FIG. 101, in accordance with at least one aspect of thepresent disclosure.

FIG. 104 is a cross-sectional elevation view of a closure drivecomprising a drive screw and a restraining collar, wherein therestraining collar is not installed onto the drive screw, in accordancewith at least one aspect of the present disclosure.

FIG. 105 is a cross-sectional elevation view of the closure drive ofFIG. 104, wherein the restraining collar is installed onto the drivescrew, in accordance with at least one aspect of the present disclosure.

FIG. 106 is a cross-sectional elevation view of a drive assembly mountedto a channel flange with a locking member, wherein FIG. 106 illustratesthe drive assembly in a pre-assembled configuration, in accordance withat least one aspect of the present disclosure.

FIG. 107 is a cross-sectional elevation view of the drive assembly andthe channel flange of FIG. 106, wherein FIG. 107 illustrates the driveassembly in an assembled configuration, in accordance with at least oneaspect of the present disclosure.

FIG. 108 is a perspective view of a surgical stapling assemblycomprising a channel jaw, a closure drive, a firing drive, and supportcomponents positioned within the channel jaw and with portions of thesurgical stapling assembly hidden for illustrative purposes, inaccordance with at least one aspect of the present disclosure.

FIG. 109 is a perspective view of the surgical stapling assembly of FIG.108, wherein various components are hidden for clarity, in accordancewith at least one aspect of the present disclosure.

FIG. 110 is a perspective view of the surgical stapling assembly of FIG.108, wherein various components are hidden for clarity, in accordancewith at least one aspect of the present disclosure.

FIG. 111 is a perspective view of a closure drive assembly comprising aclosure drive and a support element, in accordance with at least oneaspect of the present disclosure.

FIG. 112 is a perspective view of a drive screw shaft of the closuredrive assembly of FIG. 111, in accordance with at least one aspect ofthe present disclosure.

FIG. 113 is a perspective view of a retention clip of the closure driveassembly of FIG. 111, in accordance with at least one aspect of thepresent disclosure.

FIG. 114 is a perspective view of a closure drive comprising a drivescrew shaft and a closure drive nut, in accordance with at least oneaspect of the present disclosure.

FIG. 115 is a perspective view of the drive screw shaft of FIG. 114, inaccordance with at least one aspect of the present disclosure.

FIG. 116 is a cross-sectional elevation view of the closure drive ofFIG. 114, wherein a distal end of the drive screw shaft is illustratedin a pre-formed configuration, in accordance with at least one aspect ofthe present disclosure.

FIG. 117 is a cross-sectional elevation view of the closure drive ofFIG. 114, wherein the distal end of the drive screw shaft is illustratedin a formed configuration, in accordance with at least one aspect of thepresent disclosure.

FIG. 118 is a perspective view of a firing drive assembly comprising arotary firing shaft, a firing member threadably coupled to the rotaryfiring shaft, and a bailout configured to disengage the threadedengagement between the rotary firing shaft and the firing member, inaccordance with at least one aspect of the present disclosure.

FIG. 119 is a perspective view of the firing member of FIG. 118, inaccordance with at least one aspect of the present disclosure.

FIG. 120 is a cross-sectional elevation view of the firing driveassembly of FIG. 118, wherein the bailout is illustrated in anunactuated configuration, in accordance with at least one aspect of thepresent disclosure.

FIG. 121 is a cross-sectional elevation view of the firing driveassembly of FIG. 118 taken through a housing component of the bailout,wherein the bailout is illustrated in the unactuated configuration, inaccordance with at least one aspect of the present disclosure.

FIG. 122 is a cross-sectional elevation view of the firing driveassembly of FIG. 118, wherein the bailout is illustrated in an actuatedconfiguration, in accordance with at least one aspect of the presentdisclosure.

FIG. 123 is a cross-sectional elevation view of the firing driveassembly of FIG. 118 taken through a housing component of the bailout,wherein the bailout is illustrated in the actuated configuration, inaccordance with at least one aspect of the present disclosure.

FIG. 124 is a perspective view of a surgical stapling assembly, inaccordance with at least one aspect of the present disclosure.

FIG. 125 is a plan view of an anvil surface of an anvil of the surgicalstapling assembly of FIG. 124, in accordance with at least one aspect ofthe present disclosure.

FIG. 126 is a plan view of formed staple lines of the surgical staplingassembly of FIG. 124, in accordance with at least one aspect of thepresent disclosure.

FIG. 127 is an end elevation view and a side elevation view of a planarformed staple, in accordance with at least one aspect of the presentdisclosure.

FIG. 128 is an end elevation view and a side elevation view of anon-planar formed staple, in accordance with at least one aspect of thepresent disclosure.

FIG. 129 is a cross-sectional elevation view of an anvil comprising aplurality of staple forming pocket rows, in accordance with at least oneaspect of the present disclosure.

FIG. 130 is an elevation view of a sled for use with a staple cartridge,in accordance with at least one aspect of the present disclosure.

FIG. 131 is an elevation view of a first staple and a second staple foruse with a surgical stapling assembly, in accordance with at least oneaspect of the present disclosure.

FIG. 132 is an end elevation view and a side elevation view of a planarformed staple, in accordance with at least one aspect of the presentdisclosure.

FIG. 133 is an end elevation view and a side elevation view of anon-planar formed staple, in accordance with at least one aspect of thepresent disclosure.

FIG. 134 is a cross-sectional elevation view of a surgical staplingassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 135 is a partial cross-sectional elevation view of the surgicalstapling assembly of FIG. 134, in accordance with at least one aspect ofthe present disclosure.

FIG. 136 is a cross-sectional elevation view of a staple cartridge andstaple drivers of the surgical stapling assembly of FIG. 134, inaccordance with at least one aspect of the present disclosure.

FIG. 137 is a perspective view of a surgical stapling assemblycomprising a replaceable staple cartridge and a replaceable anvil plate,in accordance with at least one aspect of the present disclosure.

FIG. 138 is a perspective view of the surgical stapling assembly of FIG.137 illustrated in an unclamped configuration, wherein the anvil plateis not attached to an anvil jaw of the surgical stapling assembly, inaccordance with at least one aspect of the present disclosure.

FIG. 139 is a perspective view of the surgical stapling assembly of FIG.137, wherein the anvil plate is partially attached to the anvil jaw, inaccordance with at least one aspect of the present disclosure.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. patent application entitled METHOD OF USING A POWERED STAPLINGDEVICE, Attorney Docket No. END9298USNP1/200859-1M;

U.S. patent application entitled SURGICAL STAPLING ASSEMBLY COMPRISINGNONPLANAR STAPLES AND PLANAR STAPLES, Attorney Docket No.END9298USNP2/200859-2;

U.S. patent application entitled SURGICAL STAPLE CARTRIDGE COMPRISINGLONGITUDINAL SUPPORT BEAM, Attorney Docket No. END9298USNP3/200859-3;

U.S. patent application entitled ROTARY-DRIVEN SURGICAL STAPLINGASSEMBLY COMPRISING A FLOATABLE COMPONENT, Attorney Docket No.END9298USNP5/200859-5;

U.S. patent application entitled DRIVERS FOR FASTENER CARTRIDGEASSEMBLIES HAVING ROTARY DRIVE SCREWS, Attorney Docket No.END9298USNP6/200859-6;

U.S. patent application entitled MATING FEATURES BETWEEN DRIVERS ANDUNDERSIDE OF A CARTRIDGE DECK, attorney Docket No.END9298USNP7/200859-7;

U.S. patent application entitled LEVERAGING SURFACES FOR CARTRIDGEINSTALLATION, Attorney Docket No. END9298USNP8/200859-8;

U.S. patent application entitled FASTENER CARTRIDGE WITH NON-REPEATINGFASTENER ROWS, Attorney Docket No. END9298USNP9/200859-9;

U.S. patent application entitled FIRING MEMBERS HAVING FLEXIBLE PORTIONSFOR ADAPTING TO A LOAD DURING A SURGICAL FIRING STROKE, Attorney DocketNo. END9298USNP10/200859-10;

U.S. patent application entitled STAPLING ASSEMBLY COMPONENTS HAVINGMETAL SUBSTRATES AND PLASTIC BODIES, Attorney Docket No.END9298USNP11/200859-11;

U.S. patent application entitled MULTI-AXIS PIVOT JOINTS FOR SURGICALINSTRUMENTS AND METHODS OF MANUFACTURING SAME, Attorney Docket No.END9298USNP12/200859-12;

U.S. patent application entitled JOINT ARRANGEMENTS FOR MULTI-PLANARALIGNMENT AND SUPPORT OF OPERATIONAL DRIVE SHAFTS IN ARTICULATABLESURGICAL INSTRUMENTS, Attorney Docket No. END9298USNP13/200859-13; and

U.S. patent application entitled SURGICAL INSTRUMENT ARTICULATION JOINTARRANGEMENTS COMPRISING MULTIPLE MOVING LINKAGE FEATURES, AttorneyDocket No. END9298USNP14/200859-14.

Applicant of the present application owns the following U.S. patentapplications and U.S. patents that were filed on Dec. 19, 2017 and whichare each herein incorporated by reference in their respectiveentireties:

U.S. Pat. No. 10,835,330, entitled METHOD FOR DETERMINING THE POSITIONOF A ROTATABLE JAW OF A SURGICAL INSTRUMENT ATTACHMENT ASSEMBLY;

U.S. Pat. No. 10,716,565, entitled SURGICAL INSTRUMENTS WITH DUALARTICULATION DRIVERS;

U.S. patent application Ser. No. 15/847,325, entitled SURGICAL TOOLSCONFIGURED FOR INTERCHANGEABLE USE WITH DIFFERENT CONTROLLER INTERFACES,now U.S. patent application Publication No. 2019/0183491;

U.S. Pat. No. 10,729,509, entitled SURGICAL INSTRUMENT COMPRISINGCLOSURE AND FIRING LOCKING MECHANISM;

U.S. patent application Ser. No. 15/847,315, entitled ROBOTIC ATTACHMENTCOMPRISING EXTERIOR DRIVE ACTUATOR, now U.S. patent applicationPublication No. 2019/0183594; and

U.S. Design Pat. No. D910,847, entitled SURGICAL INSTRUMENT ASSEMBLY.

Applicant of the present application owns the following U.S. patentapplications and U.S. patents that were filed on Jun. 28, 2017 and whichare each herein incorporated by reference in their respectiveentireties:

U.S. patent application Ser. No. 15/635,693, entitled SURGICALINSTRUMENT COMPRISING AN OFFSET ARTICULATION JOINT, now U.S. patentapplication Publication No. 2019/0000466;

U.S. patent application Ser. No. 15/635,729, entitled SURGICALINSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. patentapplication Publication No. 2019/0000467;

U.S. patent application Ser. No. 15/635,785, entitled SURGICALINSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. patentapplication Publication No. 2019/0000469;

U.S. patent application Ser. No. 15/635,808, entitled SURGICALINSTRUMENT COMPRISING FIRING MEMBER SUPPORTS, now U.S. patentapplication Publication No. 2019/0000471;

U.S. patent application Ser. No. 15/635,837, entitled SURGICALINSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE TO A FRAME, nowU.S. patent application Publication No. 2019/0000472;

U.S. Pat. No. 10,779,824, entitled SURGICAL INSTRUMENT COMPRISING ANARTICULATION SYSTEM LOCKABLE BY A CLOSURE SYSTEM;

U.S. patent application Ser. No. 15/636,029, entitled SURGICALINSTRUMENT COMPRISING A SHAFT INCLUDING A HOUSING ARRANGEMENT, now U.S.patent application Publication No. 2019/0000477;

U.S. patent application Ser. No. 15/635,958, entitled SURGICALINSTRUMENT COMPRISING SELECTIVELY ACTUATABLE ROTATABLE COUPLERS, nowU.S. patent application Publication No. 2019/0000474;

U.S. patent application Ser. No. 15/635,981, entitled SURGICAL STAPLINGINSTRUMENTS COMPRISING SHORTENED STAPLE CARTRIDGE NOSES, now U.S. patentapplication Publication No. 2019/0000475;

U.S. patent application Ser. No. 15/636,009, entitled SURGICALINSTRUMENT COMPRISING A SHAFT INCLUDING A CLOSURE TUBE PROFILE, now U.S.patent application Publication No. 2019/0000476;

U.S. Pat. No. 10,765,427, entitled METHOD FOR ARTICULATING A SURGICALINSTRUMENT;

U.S. patent application Ser. No. 15/635,530, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTOR WITH AXIALLY SHORTENEDARTICULATION JOINT CONFIGURATIONS, now U.S. patent applicationPublication No. 2019/0000457;

U.S. Pat. No. 10,588,633, entitled SURGICAL INSTRUMENTS WITH OPEN ANDCLOSABLE JAWS AND AXIALLY MOVABLE FIRING MEMBER THAT IS INITIALLY PARKEDIN CLOSE PROXIMITY TO THE JAWS PRIOR TO FIRING;

U.S. patent application Ser. No. 15/635,559, entitled SURGICALINSTRUMENTS WITH JAWS CONSTRAINED TO PIVOT ABOUT AN AXIS UPON CONTACTWITH A CLOSURE MEMBER THAT IS PARKED IN CLOSE PROXIMITY TO THE PIVOTAXIS, now U.S. patent application Publication No. 2019/0000459;

U.S. Pat. No. 10,786,253, entitled SURGICAL END EFFECTORS WITH IMPROVEDJAW APERTURE ARRANGEMENTS;

U.S. patent application Ser. No. 15/635,594, entitled SURGICAL CUTTINGAND FASTENING DEVICES WITH PIVOTABLE ANVIL WITH A TISSUE LOCATINGARRANGEMENT IN CLOSE PROXIMITY TO AN ANVIL PIVOT AXIS, now U.S. patentapplication Publication No. 2019/0000461;

U.S. patent application Ser. No. 15/635,612, entitled JAW RETAINERARRANGEMENT FOR RETAINING A PIVOTABLE SURGICAL INSTRUMENT JAW INPIVOTABLE RETAINING ENGAGEMENT WITH A SECOND SURGICAL INSTRUMENT JAW,now U.S. patent application Publication No. 2019/0000462;

U.S. Pat. No. 10,758,232, entitled SURGICAL INSTRUMENT WITH POSITIVE JAWOPENING FEATURES;

U.S. Pat. No. 10,639,037, entitled SURGICAL INSTRUMENT WITH AXIALLYMOVABLE CLOSURE MEMBER;

U.S. Pat. No. 10,695,057, entitled SURGICAL INSTRUMENT LOCKOUTARRANGEMENT;

U.S. Design Pat. No. D851,762, entitled ANVIL;

U.S. Design Pat. No. D854,151, entitled SURGICAL INSTRUMENT SHAFT; and

U.S. Design Pat. No. D869,655, entitled SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following U.S. patentapplications and U.S. patents that were filed on Jun. 27, 2017 and whichare each herein incorporated by reference in their respectiveentireties:

U.S. patent application Ser. No. 15/634,024, entitled SURGICAL ANVILMANUFACTURING METHODS, now U.S. patent application Publication No.2018/0368839;

U.S. Pat. No. 10,772,629, entitled SURGICAL ANVIL ARRANGEMENTS;

U.S. patent application Ser. No. 15/634,046, entitled SURGICAL ANVILARRANGEMENTS, now U.S. patent application Publication No. 2018/0368841;

U.S. Pat. No. 10,856,869, entitled SURGICAL ANVIL ARRANGEMENTS;

U.S. patent application Ser. No. 15/634,068, entitled SURGICAL FIRINGMEMBER ARRANGEMENTS, now U.S. patent application Publication No.2018/0368843;

U.S. patent application Ser. No. 15/634,076, entitled STAPLE FORMINGPOCKET ARRANGEMENTS, now U.S. patent application Publication No.2018/0368844;

U.S. patent application Ser. No. 15/634,090, entitled STAPLE FORMINGPOCKET ARRANGEMENTS, now U.S. patent application Publication No.2018/0368845;

U.S. patent application Ser. No. 15/634,099, entitled SURGICAL ENDEFFECTORS AND ANVILS, now U.S. patent application Publication No.2018/0368846; and

U.S. Pat. No. 10,631,859, entitled ARTICULATION SYSTEMS FOR SURGICALINSTRUMENTS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Jun. 2, 2020 and which are each hereinincorporated by reference in their respective entireties:

U.S. Design patent application Ser. No. 29/736,648, entitled STAPLECARTRIDGE;

U.S. Design patent application Ser. No. 29/736,649, entitled STAPLECARTRIDGE;

U.S. Design patent application Ser. No. 29/736,651, entitled STAPLECARTRIDGE;

U.S. Design patent application Ser. No. 29/736,652, entitled STAPLECARTRIDGE;

U.S. Design patent application Ser. No. 29/736,653, entitled STAPLECARTRIDGE;

U.S. Design patent application Ser. No. 29/736,654, entitled STAPLECARTRIDGE; and

U.S. Design patent application Ser. No. 29/736,655, entitled STAPLECARTRIDGE.

Applicant of the present application owns the following U.S. Designpatent applications and U.S. patents that were filed on Nov. 14, 2016,and which are each herein incorporated by reference in their respectiveentireties:

U.S. patent application Ser. No. 15/350,621, now U.S. patent applicationPublication No. 2018/0132849, entitled STAPLE FORMING POCKETCONFIGURATIONS FOR CIRCULAR STAPLER ANVIL;

U.S. patent application Ser. No. 15/350,624, now U.S. patent applicationPublication No. 2018/0132854, entitled CIRCULAR SURGICAL STAPLER WITHANGULARLY ASYMMETRIC DECK FEATURES;

U.S. Design Pat. No. D833,608, titled STAPLING HEAD FEATURE FOR SURGICALSTAPLER; and

U.S. Design Pat. No. D830,550, titled SURGICAL STAPLER.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical device. Theterm “proximal” refers to the portion closest to the clinician and theterm “distal” refers to the portion located away from the clinician. Itwill be further appreciated that, for convenience and clarity, spatialterms such as “vertical”, “horizontal”, “up”, and “down” may be usedherein with respect to the drawings. However, surgical device are usedin many orientations and positions, and these terms are not intended tobe limiting and/or absolute. In the following description, terms such as“first,” “second,” “top,” “bottom,” “up,” “down,” and the like are wordsof convenience and are not to be construed as limiting terms.

References to items in the singular should be understood to includeitems in the plural, and vice versa, unless explicitly stated otherwiseor clear from the text. Grammatical conjunctions are intended to expressany and all disjunctive and conjunctive combinations of conjoinedclauses, sentences, words, and the like, unless otherwise stated orclear from the context. Thus, the term “or” should generally beunderstood to mean “and/or”, etc.

Recitation of ranges of values herein are not intended to be limiting,referring instead individually to any and all values falling within therange, unless otherwise indicated herein, and each separate value withinsuch a range is incorporated into the disclosure as if it wereindividually recited herein. The words “about,” “approximately” or thelike, when accompanying a numerical value, are to be construed asindicating a deviation as would be appreciated by one of ordinary skillin the art to operate satisfactorily for an intended purpose. Similarly,words of approximation such as “approximately” or “substantially” whenused in reference to physical characteristics, should be construed tocontemplate a range of deviations that would be appreciated by one ofordinary skill in the art to operate satisfactorily for a correspondinguse, function, purpose or the like.

The use of any and all examples, or exemplary language (“e.g.,” “suchas,” or the like) provided herein, is intended merely to betterilluminate the embodiments and does not pose a limitation on the scopeof the embodiments. No language in the specification should be construedas indicating any unclaimed element as essential to the practice of theembodiments.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various surgical devices disclosedherein can be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the surgical devices can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical device can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue to be stapled. The anvil ismoved toward the staple cartridge to compress and clamp the tissueagainst the deck. Thereafter, staples removably stored in the cartridgebody can be deployed into the tissue. The cartridge body includes staplecavities defined therein wherein staples are removably stored in thestaple cavities. The staple cavities are arranged in six longitudinalrows. Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples are contemplated.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired, position and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent a proximal end of the cartridge body and adistal position adjacent a distal end of the cartridge body. The sledcomprises a plurality of ramped surfaces configured to slide under thedrivers and lift the drivers, and the staples supported thereon, towardthe anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected into the tissue ahead of theknife transecting the tissue.

FIGS. 1-8 depict a surgical stapling instrument 10 configured to clamp,staple, and cut tissue of a patient. The surgical stapling instrument 10comprises a handle 20, a shaft assembly 100 attached to the handle 20,and an end effector 200. To cut and staple tissue of a patient, the endeffector 200 comprises a cartridge jaw 201 and an anvil jaw 203. Theanvil jaw 203 is pivotable relative to the cartridge jaw 203 to clamptissue between the anvil jaw 203 and the cartridge jaw 203. Once tissueis clamped between the jaws 201, 203, the surgical stapling instrument10 may be actuated to advance a firing member through the jaws 201, 203to staple and cut tissue with the end effector 200 as discussed ingreater detail below.

Discussed in greater detail below, the end effector 200 is articulatableby way of an articulation region 110 of the shaft assembly 100. Sucharticulation provides a user of the surgical stapling instrument 10 withthe ability to position and/or maneuver the end effector 200 near thetarget tissue more accurately.

The handle 20 comprises a housing 21 configured to house variousmechanical and electrical components and a handle portion 22 extendingfrom the housing 21. The handle portion 22 is configured to fit in thepalm of a user and/or be gripped and/or held by a user using thesurgical stapling instrument 10. The handle 20 further comprises variousactuators and/or triggers configured to be actuated by a user to operateone or more functions of the surgical stapling instrument 10. The handle20 comprises a closure trigger 24, a firing trigger 25, and at least onearticulation actuator 26. When actuated by a user, the closure trigger24 is configured to clamp tissue with the end effector 200 by moving theanvil jaw 203 toward the cartridge jaw 201. When actuated by a user, thefiring trigger 25 is configured to cut and staple tissue with the endeffector 200 by advancing a firing member to eject staples and cuttissue with a knife. When actuated by a user, the articulation actuator26 is configured to articulate the end effector 200 relative to theshaft assembly 100 by way of the articulation region 110. The triggersand actuators of the surgical stapling instrument 10 can either triggerone or more motors within the handle 20 to actuate various function ofthe surgical stapling instrument 10 and/or manually drive various driveshafts and components to actuate various function of the surgicalstapling instrument 10.

The handle 20 further comprises a nozzle assembly 30 configured tosupport the shaft assembly 100 therein. The nozzle assembly 30 comprisesan actuation wheel 31 configured to be rotated by a user to rotate theshaft assembly 100 and end effector 200 about a longitudinal axis LArelative to the handle 20. Such a mechanism permits the user of thesurgical stapling instrument 10 to rotate only the shaft assembly 100and/or end effector 200 without having to rotate the entire handle 20.

The handle 20 further comprises a battery 23 configured to provide powerto various electronic components, sensors, and/or motors of the surgicalstapling instrument 10. Embodiments are envisioned where the surgicalstapling instrument 10 is directly connected to a power source.Embodiments are also envisioned where the surgical stapling instrument10 is entirely manual or, non-powered, for example. Embodiments arefurther envisioned where articulation of the end effector, clamping andunclamping of the jaws, firing of the end effector staple and cuttissue, and shaft and/or end effector rotation are all powered systems.

In at least one instance, the shaft assembly 100 and the end effector200 may be modular and removable from the handle 20. In at least oneinstance, the end effector 200 may be modular in that the end effector200 can be removed from the shaft assembly 100 and replaced with adifferent end effector. In at least one instance, the shaft assembly 100and/or the end effector 200 is employable in a surgical roboticenvironment. Such an embodiment would provide powered inputs from asurgical robotic interface to actuate each function of the end effector200. Examples of such surgical robots and surgical tools are furtherdescribed in U.S. patent application Publication No. 2020/0138534,titled ROBOTIC SURGICAL SYSTEM, which published on May 7, 2020, which isincorporated by reference herein in its entirety.

In at least one instance, the shaft assembly 100 and the end effector200 are configured to be used with a surgical robot. In such aninstance, the shaft assembly 100 and the end effector 200 are configuredto be coupled to a surgical robot comprising a plurality of outputdrives. The plurality of output drives of the surgical robot areconfigured to mate with the drive systems of the shaft assembly 100 andend effector 200. In such an instance, the surgical robot can actuatethe various different functions of the end effector 200 such as, forexample, articulating the end effector about multiple differentarticulation joints, rotating the shaft assembly 100 and/or end effector200 about its longitudinal axis, clamping the end effector 200 to clamptissue between the jaws of the end effector 200, and/or firing the endeffector 200 to cut and/or staple tissue.

The shaft assembly 100 is configured to house various drive systemcomponents and/or electronic components of the surgical staplinginstrument 10 so that the end effector 200 and shaft assembly 100 may beinserted through a trocar for laparoscopic surgery. The various drivesystem components are configured to be actuated by the various triggersand actuators of the handle 20. Such components can include drive shaftsfor articulation, drive shafts for clamping and unclamping the endeffector 200, and/or drive shafts for firing the end effector 200. Suchdrive shafts may be rotated by a drive system in the handle 20 or asurgical robotic interface in the instance where the shaft assembly 100is connected to the same. In various aspects, a stapling end effectorcan include two independently rotatable drive members—one for graspingtissue and one for firing staples, for example. The stapling endeffector can further include an articulation joint, and the rotarymotions can be transmitted through the articulation joint. In variousaspects, the stapling end effector can include one or more 3D printedassemblies, which can be incorporated into an articulation, grasping, orfiring systems.

Such drive shafts may be actuated by a drive system in the handle 20 ora surgical robotic interface in the instance where the shaft assembly100 is connected to the same. Such drive shafts may comprise linearactuation, rotary actuation, or a combination thereof. A combination ofrotary actuation and linear actuation may employ a series of rack gearsand/or drive screws, for example.

In at least one instance, the shaft assembly 100 is also configured tohouse electrical leads for various sensors and/or motors, for example,positioned within the shaft assembly 100 and/or end effector 200, forexample.

The shaft assembly 100 comprises an outer shaft 101 extending from thenozzle assembly 30 to the articulation region 110 comprising dualarticulation joints, discussed in greater detail below. The articulationregion 110 allows the end effector 200 to be articulated relative to theouter shaft 101 in two distinct planes about two separate axes AA1, AA2.

Referring now primarily to FIG. 4, articulation of the end effector 200will now be described. The articulation region 110 comprises twodistinct articulation joints and two articulation actuators 150, 160.This allows the end effector 200 to be articulated in two differentplanes about two different axes AA1, AA2 independently of each other.The articulation region 110 comprises a proximal joint shaft component120, an intermediate joint shaft component 130, and a distal joint shaftcomponent 140. The proximal joint shaft component 120 is attached to adistal end of the shaft assembly 100, the intermediate joint shaftcomponent 130 is pivotally connected to the proximal joint shaftcomponent 120 and the distal joint shaft component 140, and the distaljoint shaft component 140 is fixedly attached to the end effector 200 byway of a retention ring 146. Discussed in greater detail below, thisarrangement provides articulation of the end effector 200 relative tothe shaft assembly 100 about axis AA1 and axis AA2 independently of eachother.

The proximal joint shaft component 120 comprises a proximal annularportion 121 fixedly fitted within the outer shaft 101. The proximaljoint shaft component 120 also includes a hollow passage 122 to allowvarious drive system components to pass therethrough, and furtherincludes an articulation tab 123 comprising a pin hole 124 configured toreceive articulation pin 125. The articulation pin 125 pivotallyconnects the proximal joint shaft component 120 to a proximalarticulation tab 131 of the intermediate joint shaft component 130. Toarticulate the end effector 200 about axis AA1, the articulationactuator 150 is actuated linearly either in a distal direction or aproximal direction. Such an actuator may comprise a bar or rod made ofany suitable material such as metal and/or plastic, for example. Thearticulation actuator 150 is pivotally mounted to an articulationcrosslink 151. The articulation crosslink 151 is pivotally mounted tothe intermediate joint shaft component 130 off-axis relative to thearticulation pin 125 so that when the articulation actuator 150 isactuated, a torque is applied to the intermediate joint shaft component130 off-axis relative to the articulation pin 125 by the articulationcrosslink 151 to cause the intermediate joint shaft component 130 and,thus, the end effector 200, to pivot about axis AA1 relative to theproximal joint shaft component 120.

The intermediate joint shaft component 130 is pivotally connected to theproximal joint shaft component 120 by way of the articulation pin 125which defines axis AA1. Specifically, the intermediate joint shaftcomponent 130 comprises a proximal articulation tab 131 that ispivotally connected to the proximal joint shaft component 120 by way ofthe articulation pin 125. The intermediate joint shaft component 130further comprises a hollow passage 132 configured to allow various drivesystem components to pass therethrough and a distal articulation tab133. The distal articulation tab 133 comprises a pin hole 134 configuredto receive another articulation pin 136, which defines axis AA2, and adistally-protruding key 135.

To articulate the end effector 200 about axis AA2, the articulationcable 160 is actuated to apply an articulation torque to a proximal tab141 of the distal joint shaft component 140 by way of the key 135. Thearticulation cable 160 is fixed to the key 135 such that, as the cable160 is rotated, the key 135 is pivoted relative to the intermediatejoint shaft component 130. The key 135 is fitted within a key hole 144of the distal joint shaft component 140. Notably, the key 135 is notfixed to the intermediate joint shaft component 130 and the key 135 canbe rotated relative to the intermediate joint shaft component 130. Thearticulation cable 160 also contacts the proximal tab 141 around the pinhole 142. This provides an additional torque moment from thearticulation cable 160 to the distal joint shaft component 140. Thearticulation pin 136 is received within the pin hole 142 to pivotallycouple the intermediate joint shaft component 130 and the distal jointshaft component 140.

In at least one instance, the articulation cable 160 is only able to bepulled in a proximal direction. In such an instance, only one side ofthe articulation cable 160 would be pulled proximally to articulate theend effector 200 in the desired direction. In at least one instance, thearticulation cable 160 is pushed and pulled antagonistically. In otherwords, the cable 160 can comprise a rigid construction such that oneside of the articulation cable 160 is pushed distally while the otherside of the articulation cable 160 is pulled proximally. Such anarrangement can allow the articulation forces to be divided between thepushed half of the cable 160 and the pulled half of the cable 160. In atleast one instance, the push-pull arrangement allows greaterarticulation forces to be transmitted to the corresponding articulationjoint. Such forces may be necessary in an arrangement with twoarticulation joints. For example, if the proximal articulation joint isfully articulated, more force may be required of the articulationactuator meant to articulate the distal articulation joint owing to thestretching and/or lengthened distance that the articulation actuator forthe distal articulation joint must travel.

The distal joint shaft component 140 further comprises a cutout 143 toallow various drive components to pass therethrough. The retention ring146 secures a channel 210 of the cartridge jaw 201 to the distal jointshaft component 140 thereby fixing the end effector assembly 200 to adistal end of the articulation region 110.

As discussed above, the anvil jaw 201 is movable relative to thecartridge jaw 203 to clamp and unclamp tissue with the end effector 200.Operation of this function of the end effector 200 will now bedescribed. The cartridge jaw 201 comprises the channel 210 and a staplecartridge 220 configured to be received within a cavity 214 of thechannel 210. The channel 210 further comprises an annular groove 211configured to receive the retention ring 146 and a pair of pivot holes213 configured to receive a jaw-coupling pin 233. The jaw coupling pin233 permits the anvil jaw 203 to be pivoted relative to the cartridgejaw 201.

The anvil jaw 203 comprises an anvil body 230 and a pair of pivot holes231. The pivot holes 231 in the proximal portion of the anvil jaw 203are configured to receive the jaw-coupling pin 233 thereby pivotallycoupling the anvil jaw 203 to the cartridge jaw 201. To open and closethe anvil jaw 203 relative to the cartridge jaw 201, a closure drive 250is provided.

The closure drive 250 is actuated by a flexible drive segment 175comprised of universally-movable joints arranged or formed end-to-end.In various instances, the flexible drive segment 175 can includes serial3D-printed universal joints, which are printed all together as a singlecontinuous system. Discussed in greater detail below, the flexible drivesegment 175 is driven by an input shaft traversing through the shaftassembly 100. The flexible drive segment 175 transmits rotary actuationmotions through the dual articulation joints. The closure drive 250comprises a closure screw 251 and a closure wedge 255 threadably coupledto the closure screw 251. The closure wedge 255 is configured topositively cam the anvil jaw 203 open and closed. The closure screw 251is supported by a first support body 258 and a second support body 259secured within the channel 210.

To move the anvil jaw 203 between a clamped position (FIG. 8) and anunclamped position (FIG. 7), a closure drive shaft is actuated toactuate the flexible drive segment 175. The flexible drive segment 175is configured to rotate the closure screw 251, which displaces theclosure wedge 255. For example, the closure wedge 255 is threadablycoupled to the closure screw 251 and rotational travel of the closurewedge 255 with the staple cartridge 220 is restrained. The closure screw251 drives the closure wedge 255 proximally or distally depending onwhich direction the closure screw 251 is rotated.

To clamp the end effector 200 from an unclamped position (FIG. 7), theclosure wedge 255 is moved proximally. As the closure wedge 255 is movedproximally, a proximal cam surface 256 of the closure wedge 255 contactsa corresponding cam surface 234 defined in a proximal end 235 of theanvil body 230. As the cam surface 256 contacts the cam surface 234, aforce is applied to the proximal end 235 of the anvil body 230 causingthe anvil body 230 to rotate into the clamped position (FIG. 8) aboutthe pin 233.

To open or unclamp the end effector 200 from a clamped position (FIG.8), the closure wedge 255 is moved distally by rotating the closurescrew 251 in a direction opposite to the direction that causes theclosure wedge 255 to move proximally. As the closure wedge 255 is moveddistally, a pair of nubs 257 extending from a distal end of the closurewedge 255 contact the cam surface 234 near a downwardly extending tab237 of the anvil body 230. As the nubs 257 contact the cam surface 234near the tab 237, a force is applied to the anvil body 230 to rotate theanvil body 230 into the open position (FIG. 7) about the pin 233.

In at least one instance, the profile of the cam surface 234 correspondsto the profile of the cam surface 256. For example, the cam surface 234and the cam surface 256 may match such that a maximum cam force isapplied to the anvil body 230 to cause the desired rotation of the anvilbody 230. As can be seen in FIG. 8, for example, the cam surface 234defined by the proximal end 235 of the anvil body 230 comprises a rampedsection similar to that of the upper ramped section of the cam surface256.

As discussed above, the surgical stapling instrument 10 may be actuatedto advance a firing member through the jaws 201, 203 to staple and cuttissue with the end effector 200. The function of deploying staples 226from the staple cartridge 220 and cutting tissue with knife 283 will nowbe described. The staple cartridge 220 comprises a cartridge body 221, aplurality of staple drivers 225, and a plurality of staples 226removably stored within the cartridge body 221. The cartridge body 221comprises a deck surface 222, a plurality of staple cavities 223arranged in longitudinal rows defined in the cartridge body 221, and alongitudinal slot 224 bifurcating the cartridge body 221. The knife 283is configured to be driven through the longitudinal slot 224 to cuttissue clamped between the anvil body 230 and the deck surface 221.

The deck surface 221 comprises a laterally-contoured tissue-supportingsurface. In various aspects, the contour of the deck surface 221 canform a peak along a central portion of the cartridge body 221. Such apeak can overlay a longitudinally-extending firing screw 261 thatextends through the central portion of the cartridge body 221, which isfurther described herein. The increased height along the peak can beassociated with a smaller tissue gap along a firing path of the knife283 in various instances. In certain aspects of the present disclosure,driver heights, formed staple heights, staple pocket extension heights,and/or staple overdrive distances can also vary laterally along the decksurface 221. Laterally-variable staple formation (e.g. a combination of2D staples and 3D staples) is also contemplated and further describedherein.

The staple drivers 225 are configured to be lifted by a sled 280 as thesled 280 is pushed distally through the staple cartridge 220 to ejectthe staples 226 supported by the staple drivers 225 in the staplecavities 223. The sled 280 comprises ramps 281 to contact the stapledrivers 225. The sled 280 also includes the knife 283. The sled 280 isconfigured to be pushed by a firing member 270.

To deploy the staples 226 and cut tissue with the knife 283, the endeffector 200 comprises a firing drive 260. The firing drive 260 isactuated by a flexible drive shaft 176. Discussed in greater detailbelow, the flexible drive shaft 176 is driven by an input shafttraversing through the shaft assembly 100. The flexible drive shaft 176transmits rotary actuation motions through the dual articulation joints.The firing drive 260 comprises a firing screw 261 configured to berotated by the flexible drive shaft 176. The firing screw 261 comprisesjournals supported within bearings in the support member 259 and thechannel 210. In various instances, the firing screw 261 can floatrelative to the channel 210, as further described herein. The firingscrew 261 comprises a proximal end 262 supported within the supportmember 259 and the channel 210, a distal end 263 supported within thechannel 210, and threads 265 extending along a portion of the length ofthe firing screw 261.

The firing member 270 is threadably coupled to the firing screw 261 suchthat as the firing screw 261 is rotated, the firing member 270 isadvanced distally or retracted proximally along the firing screw 261.Specifically, the firing member 270 comprises a body portion 271comprising a hollow passage 272 defined therein. The firing screw 261 isconfigured to be received within the hollow passage 272 and isconfigured to be threadably coupled with a threaded component 273 of thefiring member 270. Thus, as the firing screw 261 is rotated, thethreaded component 273 applies a linear force to the body portion 271 toadvance the firing member 270 distally or retract the firing member 270proximally. As the firing member 270 is advanced distally, the firingmember 270 pushes the sled 280. Distal movement of the sled 280 causesthe ejection of the staples 223 by engaging the plurality of stapledrivers 225, as further described herein. The driver 225 is a tripledriver, which is configured to simultaneously fire multiple staples 223.The driver 225 can comprise lateral asymmetries, as further describedherein, to maximum the width of the sled rails and accommodate thefiring screw 261 down the center of the cartridge 220 in variousinstances.

At a point during firing of the end effector 200, a user may retract thefiring member 270 to allow unclamping of the jaws 201, 203. In at leastone instance, the full retraction of the firing member 270 is requiredto open the jaws 201, 203 where upper and lower camming members areprovided on the body portion 271 which can only be disengaged from thejaws 201, 203 once the firing member 270 is fully retracted.

In various instances, the firing member 270 can be a hybrid constructionof plastic and metal portions as further described herein. In variousinstances, the threaded component 273 can be a metal component, forexample, which is incorporated into the firing member body 271 withinsert molding or over molding.

The firing member 270 can also be referred to an I-beam in certaininstances. The firing member 270 can include a complex 3D-printedgeometry comprising a lattice pattern of spaces therein. In variousinstances, 3D printing can allow the firing member or a portion thereofto act as a spring and allows a portion to more readily flex, which canimprove the force distribution and/or tolerances during a firing stroke,for example.

FIGS. 9-11 depict a surgical stapling assembly 300 comprising a shaftassembly 310 and the end effector 200 of FIGS. 1-8 attached to the shaftassembly 310. The shaft assembly 310 may be similar in many respects tovarious other shaft assemblies discussed herein; however, the shaftassembly 310 comprises a single articulation joint and an articulationbar configured to articulate the end effector 200 about the singlearticulation joint. The surgical stapling assembly 300 is configured tocut and staple tissue. The surgical stapling assembly 300 may beattached to a surgical instrument handle and/or surgical roboticinterface. The surgical instrument handle and/or surgical roboticinterface can be configured to actuate various functions of the surgicalstapling assembly 300. The shaft assembly 310 comprises an articulationjoint 320. Discussed in greater detail below, the end effector 200 isconfigured to be articulated relative to an outer shaft 311 of the shaftassembly 310 about axis AA.

The shaft assembly 310 comprises the outer shaft 311, a first shaftjoint component 330, and a second shaft joint component 350 pivotallycoupled to the first shaft joint component 330 by way of an articulationpin 354. The first shaft joint component 330 comprises a proximal tubeportion 331 configured to fit within the inner diameter of the outershaft 311. Such a fit may comprise a press fit, for example. However,any suitable attachment means can be used. The first shaft jointcomponent 330 also includes a distal portion 332. The distal portion 332comprises an articulation tab 333 comprising a pin hole 334 definedtherein and a hollow passage 335 through which various drive componentsof the surgical stapling assembly 300 can pass. Such drive componentscan include articulation actuators, closure actuators, and/or firingactuators for example.

The first shaft joint component 330 is pivotally connected to the secondshaft joint component 350 by way of the articulation pin 354. Thearticulation pin 354 is also received within a pin hole 353 of aproximally-extending articulation tab 351 of the second shaft jointcomponent 350. The pin hole 353 is axially aligned with the pin hole334. The articulation pin 354 allows the second shaft joint component350 to be articulated relative to the first shaft joint component 330about the articulation axis AA. The second shaft joint component 350further comprises a pin protrusion 352 extending from theproximal-extending articulation tab 351. Discussed in greater detailbelow, the pin protrusion 352 is configured to be pivotally coupled toan articulation drive system. The second shaft joint component 350further comprises a distal portion 355 comprising an annular groove 356configured to receive a retention ring 358. The distal portion 355 alsoincludes a hollow passage 357 through which various drive components ofthe surgical stapling assembly 300 can pass. The retention ring 358 isconfigured to hold the first jaw 201 to the second shaft joint component350 by fitting within the annular groove 211 of the cartridge channel210 and the annular groove 356 of the second shaft joint component 350.

To articulate the end effector 200 about the articulation axis AA, anarticulation bar 360 is provided. The articulation bar 360 may beactuated by any suitable means such as, for example, by a robotic ormotorized input and/or a manual handle trigger. The articulation bar 360may be actuated in a proximal direction and a distal direction, forexample. Embodiments are envisioned where the articulation systemcomprises rotary driven actuation in addition to or, in lieu of, linearactuation. The articulation bar 360 extends through the outer shaft 311.The articulation bar 360 comprises a distal end 361 pivotally coupled toan articulation link 362. The articulation link 362 is pivotally coupledto the pin protrusion 352 extending from the proximally-extendingarticulation tab 351 off center with respect to the articulation axisAA. Such off-center coupling of the articulation link 362 allows thearticulation bar 360 to apply a force to the second joint shaftcomponent 350 to rotate the second shaft joint component 350 and, thus,the end effector 200, relative to the first joint shaft component 330.The articulation bar 360 can be advanced distally to rotate the endeffector 200 in a first direction about the articulation axis AA andretracted proximally to rotate the end effector 200 in a seconddirection opposite the first direction about the articulation axis AA.

The shaft assembly 310 further comprises an articulation componentsupport structure 340 positioned within the articulation joint 320. Sucha support structure can provide support to various drive componentsconfigured to pass through the articulation joint 320 to the endeffector 200 as the end effector 200 is articulated. The supportstructure 340 may also serve to isolate the drive components from tissueremnants during use.

FIGS. 12-14 depict a surgical stapling assembly 400 comprising a shaftassembly 410 and the end effector 200 of FIGS. 1-8 attached to the shaftassembly 410. The shaft assembly 410 may be similar in many respects tovarious other shaft assemblies discussed herein; however, the shaftassembly 410 comprises a single articulation joint and an articulationcable configured to articulate the end effector 200 about the singlearticulation joint. The surgical stapling assembly 400 is configured tocut and staple tissue. The surgical stapling assembly 400 may beattached to a surgical instrument handle and/or surgical roboticinterface. The surgical instrument handle and/or surgical roboticinterface can be configured to actuate various functions of the surgicalstapling assembly 400. The shaft assembly 410 comprises an articulationjoint 420. Discussed in greater detail below, the end effector 200 isconfigured to be articulated relative to an outer shaft 411 of the shaftassembly 310 about an axis AA.

The shaft assembly 410 comprises the outer shaft 411, a first shaftjoint component 430, and a second shaft joint component 450 pivotallycoupled to the first shaft joint component 430 by way of an articulationpin 454. The first shaft joint component 430 comprises a proximal tubeportion 431 configured to fit within the inner diameter of the outershaft 411. Such a fit may comprise a press fit, for example. However,any suitable attachment means can be used. The first shaft jointcomponent 430 also includes a distal portion 432, which comprises anarticulation tab 433 comprising a pin hole 434 defined therein. Thedistal portion 432 further defines a hollow passage 435 through whichvarious drive components of the surgical stapling assembly 400 can pass.Such drive components can include articulation actuators, closureactuators, and/or firing actuators, for example.

The first shaft joint component 430 is pivotally connected to the secondshaft joint component 450 by way of the articulation pin 454. Thearticulation pin 454 is also received within a pin hole 453 of aproximally-extending articulation tab 451 of the second shaft jointcomponent 450. The articulation pin 454 allows the second shaft jointcomponent 450 to be articulated relative to the first shaft jointcomponent 430 about the articulation axis AA. The second shaft jointcomponent 450 further comprises a drive ring structure 452. The drivering structure 452 extends from the proximally-extending articulationtab 451 and further defines a portion of the pin hole 453. Discussed ingreater detail below, the drive ring structure 452 is configured to beengaged by an articulation drive system. The second shaft jointcomponent 450 further comprises a distal portion 455 comprising anannular groove 456 configured to receive a retention ring 458. A hollowpassage 457 through the distal portion 455 is configured to receivevarious drive components of the surgical stapling assembly 400therethrough. The retention ring 458 is configured to hold the first jaw201 to the second shaft joint component 450 by fitting within theannular groove 211 of the cartridge channel 210 and the annular groove456 of the second shaft joint component 450.

To articulate the end effector 200 about the articulation axis AA, anarticulation cable 460 is provided. The articulation cable 460 may beactuated by any suitable means such as, for example, by a robotic inputand/or a manual trigger on a handle of a handheld surgical instrument.The articulation cable 460 may comprise an antagonistic actuationprofile. In other words, as a first side of the articulation cable 460is pulled proximally a second side of the articulation cable 460 isallowed to advance distally like a pulley system. Similarly, as thesecond side is pulled proximally, the first side is allowed to advancedistally. The articulation cable 460 extends through the outer shaft411. The articulation cable 460 is positioned around the drive ringstructure 452 and frictionally retained thereon to permit rotation ofthe second shaft joint component 450 as the articulation cable 460 isactuated. As the articulation cable 460 is actuated, the articulationcable 460 is configured to apply a rotational torque to the drive ringstructure 452 of the second joint shaft component 450 and, thus, the endeffector 200. Such torque is configured to cause the second joint shaftcomponent 450 to rotate, or pivot, relative to the first joint shaftcomponent 430 thereby articulating the end effector 200 relative to theouter shaft 411. A first side of the articulation cable 460 can pulledto rotate the end effector 200 in a first direction about thearticulation axis AA and a second side of the articulation cable 460 canbe pulled to rotate the end effector 200 in a second direction oppositethe first direction about the articulation axis AA.

The shaft assembly 410 further comprises an articulation componentsupport structure 440 positioned within the articulation joint 420. Sucha support structure 440 can provide support to various drive componentsconfigured to pass through the articulation joint 420 to the endeffector 200 as the end effector 200 is articulated. The supportstructure 440 may also serve to isolate the drive components from tissueremnants during use.

The surgical stapling assembly 400 further comprises a closure driveshaft segment 475 and a firing drive shaft segment 476 each configuredto transmit rotary motion through the articulation joint 420 to the endeffector 200. The drive shaft segments 475, 476 are configured topassively expand and contract longitudinally as the end effector 200 isarticulated. For example, articulation can cause expansion andcontraction of the drive shaft segments 475, 476 to account for therespective longitudinal stretching of or contracting of the length ofthe drive shafts owing to articulation of the end effector 200 relativeto the shaft assembly 410. During expansion and contraction of the driveshaft segments 475, 476, the drive shaft segments 475, 476 maintainrotary driving engagement with corresponding input shafts extendingthrough the outer shaft 411 and output shafts in the end effector 200.In at least one instance, the output shafts comprise the closure screw251, which is configured to effect grasping, closing, or tissuemanipulation with the jaws 201, 203, and the firing screw 261, which isconfigured to effect clamping of the jaws 201, 203 and firing of thefiring member 270.

FIGS. 15-17 depict a surgical stapling assembly 500 comprising a shaftassembly 510 and the end effector 200 of FIGS. 1-8 attached to the shaftassembly 510. The shaft assembly 510 may be similar in many respects tovarious other shaft assemblies discussed herein; however, the shaftassembly 510 comprises a single articulation joint and drive shaftsegments configured to passively expand and contract. The surgicalstapling assembly 500 is configured to cut and staple tissue. Thesurgical stapling assembly 500 may be attached to a surgical instrumenthandle and/or surgical robotic interface. The surgical instrument handleand/or surgical robotic interface can be configured to actuate variousfunctions of the surgical stapling assembly 500. The shaft assembly 510comprises an articulation joint 520. Discussed in greater detail below,the end effector 200 is configured to be articulated about an axis AA.

The shaft assembly 510 comprises a first shaft joint component 530 and asecond shaft joint component 540 pivotally coupled to the first shaftjoint component 530 by way of an articulation pin 543. The first shaftjoint component 530 is configured to be attached to a shaft of asurgical instrument assembly and/or a surgical robotic interface. Thefirst shaft joint component 530 comprises a proximal portion 531 and anarticulation tab 533 comprising a pin hole 534 defined therein. In atleast one instance, the first shaft joint component 530 comprises ahollow passage through which various drive components of the surgicalstapling assembly 400 can pass. Such drive components can includearticulation actuators, closure actuators, and/or firing actuators forexample.

The first shaft joint component 530 is pivotally connected to the secondshaft joint component 540 by way of the articulation pin 543. Thearticulation pin 543 is also received within a pin hole 542 of aproximally-extending articulation tab 541 of the second shaft jointcomponent 540. The articulation pin 543 allows the second shaft jointcomponent 540 to be articulated relative to the first shaft jointcomponent 530 about the articulation axis AA. The second shaft jointcomponent 540 further comprises a distal portion 545 comprising anannular groove 547 configured to receive a retention ring 548 and ahollow passage 546 through which various drive components of thesurgical stapling assembly 500 can pass. The retention ring 548 isconfigured to hold the first jaw 201 to the second shaft joint component540 by fitting within the annular groove 211 of the cartridge channel210 and the annular groove 547 of the second shaft joint component 540.

Any suitable articulation drive system can be used to articulate the endeffector 200 about axis AA. In at least one instance, the end effector200 is passively articulated. In such an instance, the end effector 200may be pressed against tissue, for example, to apply a force to the endeffector 200 and cause the end effector 200 to articulate about anarticulation axis. In at least one instance, the end effector 200further comprises a spring configured to apply a neutral biasing forceto the second shaft joint segment 540, for example, to cause the endeffector 200 to be biased toward an unarticulated configuration.

The surgical stapling assembly 500 further comprises a closure driveshaft segment 575 and a firing drive shaft segment 576 each configuredto transmit rotary motion through the articulation joint 520 to the endeffector 200. The drive shaft segments 575, 576 are configured topassively expand and contract longitudinally as the end effector 200 isarticulated. Articulation causes the drive shaft segments 575, 576 toexpand and contract to account for the longitudinal stretching of orcontracting of the length of the drive shafts owing to articulation ofthe end effector 200. During expansion and contraction of the driveshaft segments 575, 576, the drive shaft segments 575, 576 maintainrotary driving engagement with corresponding input shafts and outputshafts in the end effector 200. In at least one instance, the outputshafts comprise the closure screw 251 and the firing screw 261, whichare further described herein.

FIGS. 18-20 depict a surgical stapling end effector assembly 600comprising a shaft portion 610 and an end effector 600. The end effectorassembly 600 is similar in many respects to various other end effectorassemblies disclosed herein; however, the end effector assembly 600comprises a multi-component firing member driven by a flexible firingshaft. The end effector assembly 600 is configured to cut and stapletissue. The end effector assembly 600 may be attached to a surgicalinstrument handle and/or surgical robotic interface by way of a proximaltab 611 of the shaft portion 610. The surgical instrument handle and/orsurgical robotic interface can be configured to actuate variousfunctions of the end effector assembly 600. The end effector assembly600 comprises a cartridge channel jaw 620 and an anvil jaw 660 pivotallymounted to the cartridge channel jaw 620 to clamp tissue between thecartridge channel jaw 620 and the anvil jaw 660.

The cartridge channel jaw 620 comprises a channel 630 comprising aproximal end 631, a staple cartridge 640 configured to store a pluralityof staples therein and configured to be received within the channel 630,and a support brace 650 fitted within the staple cartridge 640. Thestaple cartridge 640 and the support brace 650 are configured to beassembled together prior to installing the staple cartridge 640 into thechannel 630. Discussed in greater detail below, the support brace 650 isconfigured to further support a firing member assembly as the firingmember assembly is advanced through the end effector assembly 600.

The anvil jaw 660 is configured to form staples ejected from the staplecartridge 640. The anvil jaw 660 comprises a proximal end 661 comprisinga pair of pin holes 662 defined therein configured to receive a couplingpin 663. The anvil jaw 660 is pivotable about the coupling pin 663between an unclamped position and a fully clamped position. The couplingpin 663 is also received within a pair of pin holes 633 defined in theproximal end 631 of the channel 630. The coupling pin 663 serves topivotally mount the anvil jaw 660 to the channel 630. In at least oneinstance, the channel 630 is mounted to the shaft portion 610 by way ofa retention ring, or band, that fits around an annular groove 632 of thechannel 630 and annular groove 615 of the shaft portion 610. Theretention ring, or band, is configured to hold the channel 630 to theshaft portion 610.

The end effector assembly 600 comprises a closure drive 670 configuredto grasp tissue between the anvil jaw 660 and the cartridge channel jaw620 by pivoting the anvil jaw 660 relative to the channel 630. The endeffector assembly 600 also includes a firing drive 680 configured toclamp, staple, and cut tissue by deploying a plurality of staples fromthe staple cartridge 640. The closure drive 670 comprises a closurescrew 671 positioned within the channel 630 and a closure wedge 675threadably coupled to the closure screw 671. As the closure screw 671 isrotated, the closure wedge 675 is advanced distally or retractedproximally to open or close the anvil jaw 660, respectively. The closuredrive 670 may be actuated by any suitable means. For example, a rotarydrive shaft may extend through the shaft portion 610 from an actuationinterface, for example, to rotate the closure screw 671. Other examplesof suitable rotary drive shafts are further described herein.

The firing drive 680 comprises a flexible drive shaft 681 that isconfigured to be moved linearly through the end effector assembly 600.The flexible drive shaft 681 may be actuated by a robotic input and/or amanually-actuated drive shaft of a handle assembly, for example. Theflexible drive shaft 681 is configured to extend through a hollowpassage 614 of a distal end 613 of the shaft portion 610 and is flexibleso that the end effector assembly 600 may be articulated relative to ashaft from which the end effector 600 extends. The flexible drive shaft681 extends through a clearance slot 676 defined in the closure wedge675 and is fixedly attached to a lower firing member 682. The lowerfiring member 682 is configured to be reused with different staplecartridges.

The staple cartridge 640 comprises a disposable upper firing member 683configured to hookingly engage or, latch, onto the lower firing member682 such that the lower firing member 582 can push or, drive, the upperfiring member 683 through the staple cartridge 640 and support brace650. In other words, the firing actuation involves a two-part firingmember—a disposable upper firing member 683 incorporated into thecartridge 640 and a reusable lower firing member 682 incorporated intothe firing drive 680, which can be coupled together when the cartridge640 is seated in the elongate channel 630. The two-part firing member isfurther described herein.

The upper firing member 683 comprises an upper flange configured toengage and position the anvil jaw 660, a knife edge configured to cuttissue, and a latch portion configured to hookingly engage the lowerfiring member 682. The staple cartridge 640 further comprises a sled 684configured to engage staple drivers positioned within the staplecartridge 640 to eject staples from the staple cartridge 640. Because aknife and cutting edge are incorporated into the disposable upper firingmember 683 of the staple cartridge 640, a new and/or fresh cutting edgecan be supplied with each staple cartridge loaded into the end effectorassembly 600.

The lower firing member 682 and the upper firing member 683 areconfigured to move through the support brace 650 such that the verticalloads associated with the firing sequence are configured to bedistributed through the support brace 650, the staple cartridge 640, thechannel 630, and the anvil jaw 660. The support brace 650 may becomprised of a metal material, for example, to be inserted within thestaple cartridge 640. The support brace 650 comprises key rails 655configured to fit within corresponding key slots defined in alongitudinal slot of the staple cartridge 640. The support brace 650further comprises a longitudinal slot 653 configured to receive theknife of the upper firing member 683, a cylindrical passage 657configured to receive a portion of the upper firing member 683, aportion of the lower firing member 682, and the flexible drive shaft681. The support brace 650 further comprises vertical key extensions 656configured to be received within corresponding key holes in thecartridge deck. Such extensions may be visible through the cartridgedeck when the support brace 650 is installed within the staple cartridge640. In at least one instance, the support brace 650 is configured to beinserted into the staple cartridge 640 from the bottom of the staplecartridge 640 facing the channel 630.

The support brace 650 further comprises a proximal tab 651 and a distaltab 653, which are both configured to be engaged with the channel 630.The tabs 651, 653 are configured to distribute at least some of theforces transmitted through the assembly 600 by the firing drive 680 andcorresponding components. The distal tab 651 may serve to block theupper and lower firing members 683, 682 from being pushed through adistal end of the support brace 650 by sharing and/or redistributing theload applied to the support brace 650 by the firing drive 680 with thechannel 630.

When the staple cartridge 640 is replaced so that the end effectorassembly 600 can be reused, the staple cartridge 640 is removed from thechannel jaw 630. Removing the staple cartridge 640 from the channel jaw630 removes the upper firing member 683, the sled 684, the support brace650, and the staple cartridge 640. A fresh knife can be provided with areplacement staple cartridge.

Various embodiments disclosed herein may be employed in connection witha robotic system 700. An exemplary robotic system is depicted in FIGS.21-23, for example. FIG. 21 depicts a master controller 701 that may beused in connection with a surgical robot, such as the robotic arm slavecart 800 depicted in FIG. 22, for example. Master controller 701 androbotic arm slave cart 800, as well as their respective components andcontrol systems are collectively referred to herein as a robotic system700. Examples of such systems and devices are disclosed in U.S. Pat. No.7,524,320, entitled MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTICSURGICAL TOOLS, as well as U.S. Pat. No. 9,072,535, entitled SURGICALSTAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,which are each hereby incorporated by reference herein in theirrespective entireties. As is known, the master controller 701 generallyincludes controllers (generally represented as 703 in FIG. 21) which aregrasped by the surgeon and manipulated in space while the surgeon viewsthe procedure via a stereo display 702. The controllers 701 generallycomprise manual input devices which preferably move with multipledegrees of freedom, and which often further have an actuatable handle,trigger, or actuator for actuating tools (for example, for closinggrasping jaws, applying an electrical potential to an electrode, or thelike).

As can be seen in FIG. 22, in one form, the robotic arm cart 800 may beconfigured to actuate one or more surgical tools, generally designatedas 900. Various robotic surgery systems and methods employing mastercontroller and robotic arm cart arrangements are disclosed in U.S. Pat.No. 6,132,368, entitled MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD,the entire disclosure of which is hereby incorporated by referenceherein.

In various forms, the robotic arm cart 800 includes a base 702 fromwhich, in the illustrated embodiment, surgical tools 900 may besupported. In various forms, the surgical tool(s) 900 may be supportedby a series of manually articulatable linkages, generally referred to asset-up joints 804, and a robotic manipulator 806. In variousembodiments, the linkage and joint arrangement may facilitate rotationof a surgical tool around a point in space, as more fully described inU.S. Pat. No. 5,817,084, entitled REMOTE CENTER POSITIONING DEVICE WITHFLEXIBLE DRIVE, the entire disclosure of which is hereby incorporated byreference herein. The parallelogram arrangement constrains rotation topivoting about an axis 812 a, sometimes called the pitch axis. The linkssupporting the parallelogram linkage are pivotally mounted to set-upjoints 804 (FIG. 22) so that the surgical tool further rotates about anaxis 812 b, sometimes called the yaw axis. The pitch and yaw axes 812 a,812 b intersect at the remote center 814, which is aligned along anelongate shaft of the surgical tool 900. The surgical tool 900 may havefurther degrees of driven freedom as supported by the manipulator 806,including sliding motion of the surgical tool 900 along the longitudinalaxis “LT-LT”. As the surgical tool 900 slides along the tool axis LT-LTrelative to manipulator 806 (arrow 812 c), the remote center 814 remainsfixed relative to the base 816 of the manipulator 806. Hence, the entiremanipulator is generally moved to re-position the remote center 814.Linkage 808 of manipulator 806 may be driven by a series of motors 820.These motors actively move linkage 808 in response to commands from aprocessor of a control system. The motors 820 may also be employed tomanipulate the surgical tool 900. Alternative joint structures and setup arrangements are also contemplated. Examples of other joint and setup arrangements, for example, are disclosed in U.S. Pat. No. 5,878,193,entitled AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING, the entiredisclosure of which is hereby incorporated by reference herein.

While the data communication between a robotic component and theprocessor of the robotic surgical system is primarily described hereinwith reference to communication between the surgical tool and the mastercontroller 701, it should be understood that similar communication maytake place between circuitry of a manipulator, a set-up joint, anendoscope or other image capture device, or the like, and the processorof the robotic surgical system for component compatibility verification,component-type identification, component calibration (such as off-set orthe like) communication, confirmation of coupling of the component tothe robotic surgical system, or the like. In accordance with at leastone aspect, various surgical instruments disclosed herein may be used inconnection with other robotically-controlled or automated surgicalsystems and are not necessarily limited to use with the specific roboticsystem components shown in FIGS. 21-23 and described in theaforementioned references.

It is common practice during various laparoscopic surgical procedures toinsert a surgical end effector portion of a surgical instrument througha trocar that has been installed in the abdominal wall of a patient toaccess a surgical site located inside the patient's abdomen. In itssimplest form, a trocar is a pen-shaped instrument with a sharptriangular point at one end that is typically used inside a hollow tube,known as a cannula or sleeve, to create an opening into the body throughwhich surgical end effectors may be introduced. Such arrangement formsan access port into the body cavity through which surgical end effectorsmay be inserted. The inner diameter of the trocar's cannula necessarilylimits the size of the end effector and drive-supporting shaft of thesurgical instrument that may be inserted through the trocar.

Regardless of the specific type of surgical procedure being performed,once the surgical end effector has been inserted into the patientthrough the trocar cannula, it is often necessary to move the surgicalend effector relative to the shaft assembly that is positioned withinthe trocar cannula in order to properly position the surgical endeffector relative to the tissue or organ to be treated. This movement orpositioning of the surgical end effector relative to the portion of theshaft that remains within the trocar cannula is often referred to as“articulation” of the surgical end effector. A variety of articulationjoints have been developed to attach a surgical end effector to anassociated shaft in order to facilitate such articulation of thesurgical end effector. As one might expect, in many surgical procedures,it is desirable to employ a surgical end effector that has as large arange of articulation as possible.

Due to the size constraints imposed by the size of the trocar cannula,the articulation joint components must be sized so as to be freelyinsertable through the trocar cannula. These size constraints also limitthe size and composition of various drive members and components thatoperably interface with the motors and/or other control systems that aresupported in a housing that may be handheld or comprise a portion of alarger automated system. In many instances, these drive members mustoperably pass through the articulation joint to be operably coupled toor operably interface with the surgical end effector. For example, onesuch drive member is commonly employed to apply articulation controlmotions to the surgical end effector. During use, the articulation drivemember may be unactuated to position the surgical end effector in anunarticulated position to facilitate insertion of the surgical endeffector through the trocar and then be actuated to articulate thesurgical end effector to a desired position once the surgical endeffector has entered the patient.

Thus, the aforementioned size constraints form many challenges todeveloping an articulation system that can effectuate a desired range ofarticulation, yet accommodate a variety of different drive systems thatare necessary to operate various features of the surgical end effector.Further, once the surgical end effector has been positioned in a desiredarticulated position, the articulation system and articulation jointmust be able to retain the surgical end effector in that locked positionduring the actuation of the end effector and completion of the surgicalprocedure. Such articulation joint arrangements must also be able towithstand external forces that are experienced by the end effectorduring use.

Various surgical instruments employ a variety of different drive shaftarrangements that serve to transmit drive motions from a correspondingsource of drive motions that is supported in a handle of the surgicalinstrument or other portion of an automated or robotically controlledsystem. These drive shaft arrangements must be able to accommodatesignificant articulated orientations of the end effector whileeffectively transmitting such drive motions across the articulationjoint of the surgical instrument. In addition, due to theabove-mentioned size constraints dictated by the sizes of trocarsthrough which the instrument shafts must be inserted, these drive shaftcomponents must occupy as little space as possible within the shaft. Toaccommodate such requirements, many drive shaft arrangements compriseseveral movable elements that are coupled together in series. The smallsizes (e.g., 4 mm diameter) and numbers of components lead to difficultand lengthy assembly procedures that add to the cost and complexity ofthe device.

As further described herein, a powered stapling device can include twoindependently rotatable drive members: a first rotary drive memberconfigured to effect closing of the jaws of the end effector and asecond rotary drive member configured to effect firing of a staplecartridge installed in the end effector. The first and second rotarydrive members are flexible and configured to extend through at least onearticulation joint. In such instances, the first and second rotary drivemembers can transmit rotary actuation motions through the articulationjoint(s) when in a non-flexed configuration and when in a flexedconfiguration. Exemplary rotary drive members are further describedherein.

The powered stapling assembly further comprises a first jaw, a secondjaw, a closure drive comprising the first rotary drive member extendingthrough the articulation joint, and a firing drive comprising the secondrotary drive member extending through the articulation joint. The secondrotary drive member can be rotatable independent of the first rotarydrive member. The closure drive can be activated by a closure trigger,for example, whereupon an actuation of the closure drive effects arotation of the first rotary drive member, which transmits a rotarymotion through the articulation joint to a closure screw. The closuredrive further comprises a closure wedge threadably coupled to theclosure screw, wherein the closure wedge is configured to engage thefirst jaw to move the first jaw from an open position to a closedposition upon rotation of the first rotary drive member.

The firing drive can be activated by a firing trigger, for example,which is separate from the closure trigger. The rotation of the secondrotary drive member is separate from the rotation of the first rotarydrive member, and a closure motion is separate and distinct from afiring motion. Activation of the firing drive effects a rotation of thesecond rotary drive member, which transmits a rotary motion through thearticulation joint to a firing screw. The firing drive further comprisesa firing member threadably coupled to the firing screw, wherein thefiring member is configured to camming engage the first jaw and thesecond jaw and to move a cutting member and/or a staple-firing sled uponrotation of the second rotary drive member.

In various instances, at least one component in the powered staplingdevice can be a 3D-printed component. 3D-printed components can beincorporated into an articulation system, a closure/grasping system,and/or a firing system, as further described herein. 3D printingtechnology can be utilized to improve component capabilities in certaininstances. For example, 3D printing can allow the printed component toexhibit metamaterial properties, such that the 3D-printed componentsexhibits greater structural strength and stiffness while allowingprecision in the forming of small detailed features and optimizing otherproperties of the component such as selective flexibility and/orlubrication, for example. Exemplary 3D-printed components for thepowered stapling device are further described herein and include theflexible rotatable drive member(s), e.g. serial 3D-printed universaljoints, the firing member or I-beam, and/or the staple cartridge and/orsub-components thereof. In one instance, the staple cartridge can be acomposite plastic-metal 3D-printed component. 3D printing of variouscomponents and considerations therefor are further described herein.

A method of stapling with such surgical stapling assemblies is alsocontemplated. The method can include obtaining the surgical staplingassembly and activating, by the closure trigger, the closure drive,wherein the closure wedge is configured to engage the first jaw to movethe first jaw from an open position to a closed position upon a rotationof the first rotary drive member. The method can further includesactivating, by the firing trigger, the firing drive, wherein the firingmember is configured to camming engage the first jaw and the second jawand to advance a cutting member and a staple-firing sled during a firingmotion upon a rotation of the second rotary drive member. Variousapplications of 3D-printed components in such assemblies are furtherdescribed herein.

FIGS. 24-33 depict an end effector assembly 1000 for stapling tissue.The end effector assembly 1000 is similar to the end effector assembly600; however, the end effector assembly 1000 and the accompanyingdescription comprise further details than the end effector assembly 600.The end effector assembly 1000 comprises a shaft portion 1010 and endeffector comprising a first jaw 1011 and a second jaw 1013 movablerelative to the first jaw 1011. The end effector assembly 1000 isconfigured to cut and staple tissue captured between the jaws 1011,1013. The end effector assembly 1000 may be attached to a surgicalinstrument handle and/or surgical robotic interface by way of the shaftportion 1010. The surgical instrument handle and/or surgical roboticinterface can be configured to actuate various functions of the endeffector assembly 1000. The first jaw 1011 comprises a cartridge channel1020 and the second jaw 1013 comprises an anvil 1080 pivotally mountedto the cartridge channel 1020 by way of pin 1084 to clamp tissue betweenthe jaws 1011, 1013.

The end effector assembly 1000 further comprises a replaceable staplecartridge 1050 configured to be installed within the cartridge channel1020 and a support beam 1100 positioned within the staple cartridge1050. Discussed in greater detail below, the support beam 1100 isconfigured to provide additional internal support to the end effectorassembly 1100 within the staple cartridge 1050. The staple cartridge1050 comprises a cartridge body 1055 comprising a proximal end 1051, adistal end 1053, and a cartridge deck 1056. The cartridge body 1055further comprises a plurality of staple cavities 1057 arranged inlongitudinal rows defined in the deck 1056, and a longitudinal slot 1059defined in the deck 1056 and configured to receive a portion of a firingmember assembly discussed in greater detail below.

The replaceable staple cartridge 1050 is configured to removably store aplurality of staples within the staple cavities 1057. The staples areconfigured to be ejected from the staple cartridge and against an anvilsurface 1083 of the anvil 1080 to form the staples and staple tissuecaptured between the deck 1056 and the anvil surface 1083. To eject thestaples, a sled 1070 is pushed from a proximal end 1051 of the staplecartridge 1050 toward a distal end 1053 of the staple cartridge 1050 bythe firing member assembly. As the sled 1070 translates longitudinallywithin the staple cartridge 1050, the sled 1070 is configured to contactand lift a plurality of staple drivers supporting the staples within thestaple cartridge 1050 and form the staples against the anvil surface1083.

To open and close the anvil 1080 relative to the cartridge channel 1020and staple cartridge 1050, a closure drive 1210 is provided. Referringto FIGS. 25-27, the closure drive 1210 comprises a rotary closure drive1211 configured to be actuated by a rotary output shaft of a surgicalinstrument handle and/or robotic interface, for example. The rotaryclosure drive 1211 is supported within a proximal end 1021 of thechannel 1020 and comprises threads 1212. The closure drive 1210 furthercomprises a closure wedge 1220 comprising threads 1223 threadablycoupled to threads 1212 of the rotary closure drive 1211. Thus, as therotary closure drive 1211 is rotated, the closure wedge 1220 isconfigured to translate longitudinally within anvil cavity 1085 definedin a proximal end 1081 of the anvil 1080. The rotary closure drive 1211can be referred to as a closure screw in various instances.

The closure wedge 1220 comprises an opening cam surface 1222 and closurecam nubs 1223. To close the anvil 1080, the closure wedge 1220 is movedproximally by the rotary closure drive 1221 so that the opening camsurface 1222 defined thereon engages the proximal end 1081 of the anvil1080 thereby pivoting the anvil 1080 about the pin 1084 toward a closedposition. To open the anvil 1080, the closure wedge 1220 is moveddistally by the rotary closure drive 1221 so that the closure cam numbs1223 engage the proximal end 1081 of the anvil 1080 thereby pivoting theanvil 1080 about the pin 1084 toward an open position. The closure wedge1220 further comprises a u-shaped slot 1221 configured to allow alinearly-actuated firing drive to pass therethrough, discussed ingreater detail below.

To fire the end effector assembly 1000, a firing drive 1250 is provided.The firing drive 1250 comprises a flexible firing shaft 1251 configuredto be actuated by a linear output shaft of a surgical instrument handleand or robotic interface. The flexible firing shaft 1251 passes throughthe u-shaped slot 1221 of the closure wedge 1220 toward a firingassembly comprising a lower firing member 1260 and an upper firingmember 1270. The firing shaft 1251 comprises a distal end 1252 fixedwithin a drive slot 1263 defined in a guide portion 1265 of the lowerfiring member 1260. In at least one instance, the firing shaft 1251 isrotatably supported (e.g. journaled) within the drive slot 1263 suchthat the firing shaft 1251 may push and pull the lower firing member1260 while being able to rotate within the drive slot 1263. Such aconfiguration can permit rotation of the flexible firing shaft 1251relative to the lower firing member 1260 while maintaininglinearly-actuatable engagement. The anvil 1080 further comprises anupper anvil cap 1090 configured to be attached to the anvil 1080. Theanvil cap 1090 can be welded to the anvil 1080, for example, and canserve to strengthen the anvil 1080. The channel 1020 can also comprise achannel cap 1030.

The lower firing member 1260 comprises a lower camming flange 1261extending laterally from the lower firing member 1260, an upper cammingflange 1262 extending laterally from the lower firing member 1260, andthe guide portion 1265 configured to be received within the support beam1100, discussed in greater detail below. The lower camming flange 1261is configured to engage the channel 1020 during a firing stroke tomaintain a defined clamped tissue gap between the staple cartridge 1050and the anvil 1080. The upper camming flange 1262 is configured toengage the support beam 1100 during a firing stroke. Discussed ingreater detail below, providing multiple camming flanges within thefiring assembly can aid in distributing clamping forces within the endeffector assembly 1000. When discussing the camming flanges, it shouldbe understood that, as can be seen in the drawings, the flanges extendlaterally outwardly from both sides of the primary body portions of thefiring members.

An upper firing member 1270 is also provided. The upper firing member1270 is configured to be advanced through the firing stroke by the lowerfiring member 1260. The guide portion 1265 is configured to push a guideportion 1274 of the upper firing member 1270. The upper firing member1270 comprises an upper camming flange 1272 extending laterally from theupper firing member 1270, a lower camming flange 1273 extendinglaterally from the upper firing member 1270, and the guide portion 1274configured to be received within the support beam 1100, discussed ingreater detail below. The upper camming flange 1272 is configured toengage the anvil 1080 during a firing stroke. Specifically, the uppercamming flange 1272 is configured to apply clamping forces to the anvil1080 within a slot 1086. At the beginning of a firing stroke, the uppercamming flange 1272 is configured to engage a proximal ramp portion 1087of the slot 1086 to begin applying clamping forces within the endeffector assembly 1000.

The lower camming flange 1273 of the upper firing member 1270 isconfigured to engage the support beam 1100 during a firing stroke. Sucha lower camming flange 1273 can provide an additional camming flangewithin the firing member assembly to help distribute clamping forceswithin the end effector assembly 1000. The upper firing member 1270further comprises a cutting edge, or knife, 1271 configured to cuttissue clamped between the staple cartridge 1050 and the anvil 1280. Theupper firing member 1270 further comprises a drive surface 1276 definedon the front of the upper firing member 1270. The drive surface 1276 isconfigured to push a drive flange 1071 of the sled 1070. As the sled1070 is advanced through the end effector assembly 1000 by the upperfiring member 1270, sled rails 1072 of the sled 1070 are configured toengage staple drivers, lift the staple drivers, and eject the staples tostaple tissue.

In at least one instance, the upper firing member 1270 is disposable andthe lower firing member 1260 is reusable. In such an instance, the upperfiring member 1270 is replaced and comes with the staple cartridge 1050positioned in a ready to install, or ready to fire position. In otherwords, every time a new staple cartridge is to be installed, the userreceives a new upper firing member. Such a configuration can provide afresh knife with each fresh staple cartridge.

The lower firing member 1260 comprises a receiving hook slot 1264 andthe upper firing member 1270 comprises a hook portion 1275 configured tobe received within the receiving hook slot 1264. The staple cartridge1050 including the sled 1070 and the upper firing member 1270 may beinstalled at an angle similar to that of the anvil 1080 positioned inits open position. Such an angle allows a user to latch, or hook, theupper firing member 1270 into the lower firing member 1260 as the userinstalls the staple cartridge 1050 into the channel 1020. In at leastone instance, the lower firing member 1260 is configured to push andpull the upper firing member 1270 within the end effector assembly 1000by pushing the guide portion 1274 with the guide portion 1265 andpulling the hook portion 1275 with the hook portion 1264. In certaininstances, alignment and/or leveraging features intermediate the staplecartridge 1050 and the channel 1020 are configured to interact to ensureproper alignment and insertion of the staple cartridge 1050.

Because a fresh and disposable knife can be provided each time a staplecartridge is installed, the staple cartridge 1050 further comprisesknife guard tabs 1060 extending upwardly from the deck 1056. The knifeguard tabs 1060 may protect a user from getting cut by the knife edge1271 when handling the staple cartridge 1050. The knife guard tabs 1060may also prevent tissue from being inadvertently cut when tissue isbeing clamped by the end effector assembly 1000 and prior to the cuttingmotion. If tissue leaks toward the knife guard tabs 1060 prior tofiring, the knife guard tabs 1060 will protect unstapled tissue beforefiring.

As discussed above, various types of firing and clamping forces arepresent within the end effector assembly 1000. The support beam 1100 isconfigured to help distribute the clamping forces within the endeffector assembly to various components to reduce the possibility of anysingle component failing by increasing the distribution of forces withinthe end effector assembly. In end effectors without a support beam,clamping forces may be primarily applied to a channel and an anvil. Theend effector assembly 1000 permits a greater distribution of clampingforces within the end effector assembly 1000.

Referring primarily to FIGS. 28-33, the internal support beam 1100 ispositioned within an internal longitudinal channel 1060 of the staplecartridge 1050. The internal support beam 1100 may comprise of astronger material than the cartridge body 1055. In at least oneinstance, the support beam 1100 comprises of a metal material and thecartridge body 1055 comprises of a polymer. In such an instance, thesupport beam 1100 can help distribute clamping forces within the endeffector assembly 1100 by making the support beam 1100 of a materialwhich is stronger than the material of the cartridge body 1055.

The support beam 1100 comprises an upper surface 1110 comprising aplurality of protrusions 1111 protruding therefrom and configured to bereceived within corresponding slots 1058 defined the deck 1056 of thestaple cartridge 1050. The protrusions 1111 may provide additionallateral and longitudinal support within the staple cartridge 1050. Inother words, the protrusions 1111 can prevent the support beam 1100 fromsliding laterally or longitudinally relative to the cartridge body 1055.The protrusions 1111 can also help align the support beam 1100 to thecartridge body 1055 when assembling the support beam 1100 and thecartridge body 1055. In at least one instance, the support beam 1100 isinstalled in the staple cartridge 1050 prior to packaging. In such aninstance, the replaceable staple cartridge 1050 already comprises thesupport beam 1100. Thus, when the staple cartridge 1050 is replaced, anew support beam is provided.

The support beam 1100 may be slid vertically into the internallongitudinal channel 1060 of the cartridge body 1055 from the bottom ofthe staple cartridge 1050 opposite the deck 1056. The cartridge body1055 further comprises lateral rails, or ledges, 1062 defined on channelwalls 1061 of the internal longitudinal channel 1060. The rails 1062 areconfigured to fit within corresponding slots 1109 defined in the sidesof the support beam 1100. The rails 1062 are configured to hold thesupport beam 1100 within the cartridge body 1055 and prevent the supportbeam 1100 from falling out of the bottom of the cartridge body 1055. Theinternal longitudinal channel 1060 further comprises an upper surface1063 defined underneath a thickness of the deck 1056. The upper surface1110 of the support beam 1100 is configured to abut the upper surface1063.

In at least one instance, the cartridge body 1055 is overmolded onto thesupport beam 1100. Such a configuration can provide various internalfeatures otherwise difficult to provide where the parts need to beseparately manufactured and assembled after they are manufactured. In atleast one instance, the cartridge body 1055 is overmolded and/or insertmolded onto the support beam 1100 and the upper firing member 1270. Insuch instances, the staples, staple drivers, and sled can be assembledinto the staple cartridge 1050 and support beam 1100 after theovermolding process is complete. In at least one instance, the supportbeam 1100 is insert molded into the staple cartridge 1050.

The support beam 1100 further comprises a longitudinal cavity 1120comprising a lower cam slot 1121, an upper cam slot 1123, and acylindrical slot 1122. The lower cam slot 1121 is configured to receivethe upper camming flange 1262 of the lower firing member 1260. The uppercam slot 1123 is configured to receive the lower camming flange 1273 ofthe upper firing member 1270. The cylindrical slot 1122 is configured toreceive the guide portion 1274, the guide portion 1265, and the flexiblefiring shaft 1251 as the upper and lower firing members 1270, 1260 areadvanced through the end effector assembly 1000. The longitudinal cavity1120 is also configured to receive the drive flange 1071 of the sled1070 as the sled 1070 is pushed by the upper firing member 1270. In atleast one instance, the flexible firing shaft 1251 is configured to beclosely received within the cylindrical slot 1122 such that the crosssectional profile of each substantially matches. In such an instance,the cylindrical slot 1122 can serve to help prevent buckling of theflexible firing shaft 1251 as the flexible firing shaft 1251 is advancedthrough the cylindrical slot 1122. As compressive forces are experiencedby the flexible firing shaft 1251, the cylindrical slot 1122 can supportthe length of the flexible firing shaft 1251 positioned therein and helpto prevent buckling of the flexible firing shaft 1251.

As discussed above, the support beam 1100 is configured to helpdistribute clamping forces applied to the end effector assembly 1100 bythe flanges 1272, 1273, 1262, and 1261. The guide portions 1274, 1265may also apply vertical clamping forces by way of the flanges 1272,1273, 1262, and 1261 and can also help distribute the clamping forcesthrough the support beam 1100. As the upper firing member 1270 and thelower firing member 1260 are advanced through the end effector assembly1000, the flanges 1272, 1273, 1262, and 1261 can apply vertical clampingforces to the anvil 1080, the channel 1020, and the support beam 1100.These forces may be primarily distributed between the anvil 1080, thechannel 1020, and the support beam 1100; the components stronger thanthe staple cartridge 1050 that may primarily consist of metal.Distributing the clamping loads through these components can reduce thevertical crushing forces applied to the cartridge body 1055, itself.Such an arrangement can also reduce the likelihood of any of the flanges1272, 1273, 1262, and 1261 shearing from their respective firing memberbody because they can share the vertical clamping forces along thevertical length of the end effector assembly 1000. The support beam 1100can also provide additional support between the channel 1020 and theanvil 1080 rather than relying on just the channel 1020 and the anvil1080 to handle all of the clamping forces applied by only a channelflange and an anvil flange.

In at least one instance, the upper and lower firing members 1270, 1260are referred to as dual I-beams. This configuration can allow for acentral longitudinal cavity such as the cylindrical slot 1122 defined inthe support beam 1100 positioned between the upper flange 1262 of thelower firing member 1260 and the lower flange 1273 of the upper firingmember 1270.

The guide portions 1265, 1274 may also help strengthen the firingmembers 1260, 1270 by providing a rounded portion engaged with thesupport beam 1100. The rounded portions can also provide a source ofstrength to the firing members 1260, 1270 because they can handlesignificant vertical forces. To fail, they would likely requireshear-type failure rather than a bending-type failure making the roundedportions stronger than lateral flanges in certain instances. Havingfiring members with both lateral flanges and rounded portions canincrease the overall strength of the firing assembly as it pertains tovertical clamping forces experienced within the end effector assembly1000. All of the vertical clamping forces can serve to maintain apredefined tissue gap between the staple cartridge 1050 and the anvil1080.

Longitudinal loads are also experienced within an end effector assembly1000. For example, a firing member assembly can experience longitudinalloads applied by tissue on the knife 1271. A firing member assembly canalso experience longitudinal loads generated by the clamping forcesapplied to the channel 1020 and the anvil 1080. Longitudinal loads canalso be experienced when the firing member assembly abuts components inits proximal-most position. Longitudinal loads can also be experiencedwhen the firing member assembly and/or sled abuts the distal end of theend effector assembly 1000. In such an instance, the sled and/or firingmember assembly components may be pushed distally into the nose of thestaple cartridge, anvil, and/or support beam. The end effector assembly1000 also comprises features to help distribute these longitudinal loadswithin the end effector assembly 1000.

The support beam 1100 comprises a proximal hook 1102 (FIG. 29) and adistal hook 1104 (FIG. 30) extending downwardly from the support beam1100. The proximal hook 1102 is configured to be received within acorresponding channel aperture 1023 defined in the proximal end 1021 ofthe channel 1020. The proximal hook 1102 can be latched into theaperture 1023 as the staple cartridge 1050 and support beam 1100 areinstalled into the channel 1020. The hook 1102 may be installed with anaudible click, for example, to inform a user of successful installation.The hook 1102 may also be visible from underneath the channel 1020 sothat a user can see if the hook 1102 has been properly engaged with thechannel 1020. The distal hook 1104 is configured to be received within acorresponding channel aperture 1024 defined in the distal end 1022 ofthe channel 1020. The distal hook 1104 may be snapped into the aperture1024 by way of the sloped surface 1104′ after the proximal hook 1102 issuccessfully installed into the proximal end 1021 of the channel 1022.The hooks 1102, 1104 may serve to distribute longitudinal loadsexperienced within the end effector assembly 1000. The distal hook 1104can cause the firing members 1260, 1270 to apply forces primarily to thechannel 1020 instead of the distal end, or nose, 1053 of the staplecartridge 1050 at the end of the firing stroke. Such a configuration mayprotect the integrity of the nose 1053 of the staple cartridge 1050which is typically made of a more brittle material than the channel1020. The channel 1020 can serve to support the distally applied forcesby the firing members 1260, 1270 in lieu of the cartridge nose 1053. Thedistal end 1103 of the support beam 1100 also comprises a fitted profileconfigured to fit within the nose 1053 of the staple cartridge 1053.

As discussed above, the upper firing member 1270 can be disposable andremoved with the staple cartridge 1050 so that a new upper firing membercan be installed within a new staple cartridge. In such an instance, theupper firing member 70 can be moved into its proximal-most positionafter a firing stroke is completed. When the upper firing member 1270 ispulled into its proximal-most position, the anvil 1080 may be pivotedopen by the closure drive 1210. As the anvil 1080 is pivoted open, theengagement surface 1087 may tilt the upper firing member proximallyrelative to the lower firing member 1260 and unlatch the hook 1275. Atsuch point, the staple cartridge 1050 and upper firing member 1270 canbe pried and/or unsnapped out of the channel 1020 so that a new staplecartridge, support beam, and upper firing member may be installed in thechannel 1020 and the end effector assembly 1000 can be used again.

FIGS. 34 and 35 depict portions of a stapling assembly 1200 comprising asupport beam 1210, a firing member, such as a sled, 1220, and a couplingmember 1201 coupling the firing member 1220 to the support beam 1210.The stapling assembly 1200 can be used within any suitable staplecartridge such as those disclosed herein. The support beam 1210comprises a central drive cavity 1211 configured to receive at least aportion of a firing beam and/or firing member assembly, such as theupper and lower firing members discussed above, an upper slot 1214configured to receive at least a portion of a firing member assembly,and a pair of horizontal slots 1213 configured to receive the couplingmember 1201. The upper slot 1214 may be aligned with a longitudinal slotdefined in a deck of a staple cartridge. The coupling member 1201 maycomprise of a pin, for example.

The firing member 1220 is configured to eject staples from a staplecartridge as the firing member is advanced through a staple cartridgeand the support beam 1210. The support beam 1210 further comprises atleast partially curved walls, or flanges, 1212 partially encompassingthe central drive cavity 1211. The firing member 1220 comprises driveramps 1222 configured to push staples and/or staple drivers out of astaple cartridge.

In at least one instance a firing member assembly is configured to pushon only the firing member 1220 to advance the firing member 1220 througha staple cartridge and the support beam 1210. Such a configuration canpermit the majority of firing force to be applied directly to the firingmember 1220. In at least one instance, a firing member assembly isconfigured push on both the coupling member 1201 and the firing member1220 to advance the firing member 1220 through a staple cartridge andthe support beam 1210. Such a configuration can permit sharing of theapplied firing forces and can distribute the applied firing forcesthroughout the coupling member 1201 and the firing member 1220.

In at least one instance, a firing member assembly is configured to pushon only the coupling member 1201 to advance the firing member 1220through a staple cartridge and the support beam 1210. Such aconfiguration can permit a more focused firing force application on acomponent made of metal rather than a component made of a polymer incertain instances. For example, the firing member 1220 may consist of apolymer while the coupling member 1201 may comprise of a metal. In atleast one instance, the firing member 1220 and the coupling member 1201comprise the same material.

Applying the firing forces to a coupling member such as the couplingmember 1201, for example, can spread out the application of the firingforces laterally with respect to the longitudinal travel path of thefiring member 1220. This lateral distribution can help distribute firingforces throughout the support beam 1210. The firing member 1220 isconfigured to surround a bottom of the support beam 1210. Such aconfiguration can permit the use of differently sized sleds within acartridge channel.

FIGS. 36 and 37 depict a stapling assembly 1300 configured to be usedwith any suitable staple cartridge disclosed herein. The staplingassembly 1300 comprises a firing assembly 1310 configured to be actuatedby a firing shaft, a support beam 1340 configured to be positioned witha staple cartridge, and a sled, or firing member, 1350 configured toeject staples from the staple cartridge. The firing assembly 1310comprises a lower firing member 1320 and an upper firing member 1330configured to be actuated by the lower firing member 1320. The lowerfiring member 1320 comprises a drive portion 1323 configured to drivethe upper firing member 1330, a shaft connection cavity 1321 configuredto receive a firing shaft therein, and a bottom 1322. The upper firingmember 1330 comprises an upper flange 1331 configured to engage ananvil, for example, and a lower flange 1332 configured to engage aportion of the support beam 1340.

The support beam 1340 comprises a longitudinal channel 1343 configuredto receive the firing member assembly 1310 therein and flared ledges1341 configured to support the firing member 1350. The lower flange 1332is configured to apply camming forces to the support beam 1340 withinthe longitudinal channel 1343. Collectively, the upper flange 1331 andthe lower flange 1332 are configured to maintain a predefined tissue gapbetween a staple cartridge and an anvil.

The sled 1350 comprises guide arms 1351 configured to be supported bythe flared ledges 1341 of the support beam 1340 and drive ramps 1352configured to eject staples from a staple cartridge. The sled 1350 canbe slid onto one end of the support beam 1340 for assembly. The sled1350 hangs from the flared ledges 1341. Such a configuration can permituse of differently sized sleds for different cartridges and the samesupport beam 1340. The firing member assembly 1310 is configured to pushthe sled 1350 through a firing stroke. The flared ledges 1341 canfurther serve to transfer vertical camming forces applied by the firingmember assembly 1310 to the staple cartridge. In at least one instance,the vertical camming forces applied by the firing member assembly 1310are isolated from the staple cartridge. In such an instance, the supportbeam 1340 is configured to experience most, if not all, of the verticalclamping forces in addition to the anvil and/or channel, for example.Such a configuration can focus vertical clamping forces onto strongercomponents such as those components made of metal.

Alternative support beam geometries are also contemplated. For example,FIG. 38 depicts a support beam 1410 configured to be positioned within astaple cartridge such as those staple cartridges disclosed herein. Thesupport beam 1410 is configured to help distribute vertical clampingforces throughout an end effector assembly. The support beam 1410comprises a substantially round, oval, or radial outer perimeter 1411and thus cross-sectional profile. The support beam 1410 furthercomprises an upper channel 1413 and a lower channel 1415. The channels1413, 1415 are configured to receive one or more components of a firingmember assembly such those disclosed herein. The channel 1413 comprisesa cylindrical cavity portion 1414 and can receive a guide portion of anupper firing member, for example. The channel 1415 comprises acylindrical cavity portion 1416 and can receive a guide portion of alower firing member, for example. The substantially radialcross-sectional profile of the support beam can serve to strengthen thesupport beam 1410. In such a configuration, it is less likely that thesupport beam 1410 will fail due to bending loads applied by verticalclamping forces. Rounded camming flanges can also be used with thesupport beam 1410. Rounded camming flanges can provide a strengthenedflange system within an end effector assembly, as further describedherein.

FIG. 39 depicts a support beam 1420 configured to be positioned within astaple cartridge such as those staple cartridges disclosed herein. Thesupport beam 1420 is configured to help distribute vertical clampingforces throughout an end effector assembly. The support beam 1420comprises a substantially round, or radial, outer perimeter 1421 andthus cross-sectional profile. The support beam 1410 further comprises alower flange 1424 extending from the substantially round, or radial,outer perimeter 1421. In at least one instance, the lower flange 1424 isconfigured to engage the bottom of a staple cartridge, for example, andcan comprise one of the flanges in a multi-flange system. In such aninstance, a firing member of a firing member assembly may comprise aflange-receiving cavity rather than a laterally extending flange.

The support beam 1420 further comprises an upper channel 1422. Thechannel 1422 is configured to receive one or more components of a firingmember assembly such those disclosed herein. The channel 1422 comprisesa cylindrical cavity portion 1423 and can receive a guide portion of anupper firing member, for example.

FIGS. 40 and 41 depict a stapling assembly 1500 configured to cut andstaple tissue of a patient. The stapling assembly 1500 comprises astaple cartridge 1510 configured to removably store a plurality ofstaples therein, a sled 1520 comprising drive ramps 1521 configured toeject the staples stored within the staple cartridge 1510, and an I-beam1570 configured to push the sled 1520 through the staple cartridge 1510.The stapling assembly 1500 further comprises a cartridge support 1530positioned within a longitudinal channel 1511 of the staple cartridge1510 defined by inner walls 1512 and ledges 1513. The cartridge support1530 comprises an upper cam channel 1533 configured to receive a lowercamming flange 1572 of the I-beam 1570 and a lower cam channel 1531configured to receive a camming flange 1523 of the sled 1520.

The camming flange 1523 comprises a support portion 1524 extendingupwardly into the cam channel 1531 and a flange 1525. The flange 1525extends from the support portion 1524 to form a T-shape; however, othergeometries are also contemplated. As the sled 1520 is advanced throughthe staple cartridge 1510 and the cartridge support 1530, the flange1525 moves through the cam channel 1531. The cartridge support 1530 isconfigured to support the vertical clamping forces applied within thestapling assembly 1500 by the I-beam 1570 and the sled 1520.

The stapling assembly 1500 further comprises a deck plate 1560positioned on a deck surface 1514 of the staple cartridge 1510. The deckplate 1560 may help distribute clamping forces within the staplingassembly 1500. The deck plate 1560 may be comprised of a metal material,for example. The deck plate 1560 comprises a plurality of apertures 1561configured to be aligned with staple cavities defined in the staplecartridge 1510. The deck plate 1560 further comprises a longitudinalslot 1562 aligned with the longitudinal channel 1511. The cartridgesupport 1530 further comprises a central cylindrical support cavity 1535configured to receive at least a portion of a firing member assembly.For example, the central cylindrical support cavity 1535 is configuredto receive a linear actuator, guide portions of firing membercomponents, and/or a guide portion of a sled, for example.

Referring primarily to FIG. 41, the cartridge support 1530 compriseslongitudinal slots 1536 configured to receive ledges 1513 of the staplecartridge 1510. The width 1541 and the height 1542 can be adjusted toaccommodate different size cartridges, staples, and/or staple drivers,for example. The width 1541 and height 1542 of the cartridge support1530 can also be adjusted for different tissue gap distances between thestaple cartridge 1510 and an anvil. In at least one instance, the width1541 and height 1542 can be adjusted to tune the clamping loaddistribution for different scenarios. For example, a stapling instrumentwith lower clamping forces may be served better by a cartridge supportwith a thinner width than the cartridge support 1530.

FIG. 42 depicts a cartridge support 1600 configured to be positionedwithin a staple cartridge such as those staple cartridges disclosedherein. The cartridge support 1600 comprises a cylindrical centralportion 1606 defining a central longitudinal guide cavity 1605, an uppercam channel 1603, and lower cam channel 1601 each configured to receivea camming flange. The central longitudinal guide cavity 1605 can beconfigured to receive guide portions of one or more components a firingassembly such as a sled, upper firing member, or lower firing member.The central longitudinal guide cavity 1605 can also be configured toreceive a firing shaft therein. The cam channels 1601, 1603 comprise aradial cross section. Such an arrangement can reduce the likelihood offailure of the respective flanges received therein due to bending loads.

FIG. 43 depicts a stapling assembly 1700 comprising a cartridge support1710 and a sled 1720. The cartridge support 1710 comprises alongitudinal slot 1711 configured to receive at least a portion of thesled 1720 therethrough during a firing stroke. The sled 1720 comprises abottom portion 1721 configured to be threadably coupled to a firingdrive screw, for example, and a first arm 1722 extending from the bottomportion 1721 upwardly around a first side of the cartridge support 1710.The sled 1720 further comprises a second arm 1723 extending from thebottom portion 1721 upwardly around a second side of the cartridgesupport 1710. The arms 1722, 1723 each comprise a guide tooth 1724,1725, respectively, received within corresponding slots 1712, 1713,respectively, of the cartridge support 1710. The engagement features forsecuring the sled 1720 in the cartridge support 1710 are asymmetricrelative to a vertical centerline plane. More specifically, the arms1722, 1723 comprise different geometries, e.g. different heights, andthe guide teeth 1724, 1724 also comprise different geometries, e.g.different lengths and/or shapes. The slots 1712, 1713 comprise a profilesimilar to the tooth they are configured to receive. Such aconfiguration can provide a means for ensuring that the sled 1720 isinstalled in the correct direction. Such a configuration can also allowfor fine tuning of loads applied to the sled 1720 through thedifferently sized arms 1722, 1723.

FIG. 44 depicts a sled 1730 configured to be used with any suitablestaple cartridge and/or staple cartridge support discussed herein.Unlike the sled 1720, the sled 1730 comprises arms 1732 comprising thesame height and profile. The arms 1732 extend from bottom portion 1731and comprise teeth 1733 extending outwardly with respect to the sled1731. Such a sled can be configured to be guided by a cartridge supportand/or staple cartridge within internal guide slots defined in thecartridge support and/or staple cartridge owing to the outwardlyextending teeth 1733.

FIG. 45 depicts a cartridge support 1740 comprising a central cavity1741 configured to receive the sled 1730 (FIG. 45), for example,therein. The central cavity 1741 comprises laterally opposed slots 1742comprising vertical installation portions 1743 configured to receiveteeth 1733, for example. A firing member assembly can be configured topush the sled 1730 through the cartridge support 1740 during a firingstroke.

FIG. 46 depicts a stapling assembly 1800 comprising a cartridge jaw1810, an anvil 1820, a firing member 1840, and a sled 1830 configured tobe pushed through the cartridge jaw 1810 by the firing member 1840. Thesled 1830 is pinned to the firing member 1840 by way of a pin 1812. Asthe firing member 1840 is advanced by a firing shaft, for example, thesled 1830 is pushed by way of the pin 1812. The firing member 1840comprises a bottom flange 1842 configured to be received within a slot1811 of the cartridge jaw 1810 and an upper flange 1841 configured to bereceived within a slot 1821 defined in the anvil 1820.

FIG. 47 depicts a surgical stapling assembly 1900 comprising a cartridgechannel 1910 and an anvil 1920. The surgical stapling assembly 1900further comprises a support beam 1940 and a staple cartridge 1970. Thesurgical stapling assembly 1900 further comprises a firing member 1950comprising an upper flange 1952 configured to engage the anvil 1920 anda lower flange 1951 configured to engage the support beam 1940. Thesurgical stapling assembly further comprises a sled 1930 pinned to thestaple cartridge 1970 and the support beam 1940 by way of pin 1960.

In various instances, firing member assemblies configured to be drivenby firing drive screws positioned within an end effector can bind duringthe firing stroke. The binding can exist at the threaded couplingengagement between the firing member assembly and the firing drivescrew. Such binding can be attributed to the location of the transfer ofdrive forces from the drive screw to the firing member assembly incertain instances. In various instances, the location of the transfer ofdrive force occurs immediately adjacent the threads of the firing drivescrew and the receiving threads of the firing member assembly. Becausethe firing drive screw is generally positioned within a cartridgechannel jaw, the location of the transfer force is positioned a distanceaway from the center of mass and/or drive center of the firing memberassembly. This application of force can cause a torque load applied tothe firing member assembly which may cause the threaded engagementbetween the firing drive screw and the firing member assembly to bind.

Various firing member assemblies are disclosed herein which may move thelocation of the transfer force closer to the center of mass and/or drivecenter of the firing member assembly to reduce incidences of binding.More specifically, these configurations can reduce the likelihood ofthread binding between the firing member assembly and the firing drivescrew. Such configurations may also provide a more efficient transfer offorce from the firing drive screw, to the firing member assembly, to thesled and/or cutting member. A more direct force application to the sledand/or cutting member by the firing member assembly can reduce the overdrive force necessary of the firing drive screw. Such a direct forceapplied near the center of the firing member assembly can also reducethe required drive force to maintain a predefined tissue gap using theupper and lower camming flanges of the firing member assembly. This canbe attributed to centering the force application to the firing memberassembly at a vertical center, or near the center, of the cammingflanges.

FIGS. 48 and 49 depict a firing member assembly 2000 configured to beused within a surgical stapling assembly such as those disclosed herein.The firing member assembly 2000 is configured to be actuated by a firingdrive screw to cut and staple tissue. Specifically, the firing memberassembly 2000 is configured to push a sled to deploy staples from astaple cartridge. In at least one instance, the sled comprises a cuttingmember configured to cut tissue as the firing member assembly 2000 isactuated through an end effector. In another instance, the cuttingmember is part of the firing member assembly. The firing member assembly2000 is further configured to maintain a predefined tissue gap byproviding camming flanges, which engage an upper jaw and lower jaw of anend effector.

The firing member assembly 2000 comprises a primary body portion, ordistal head, 2010 and a drive nut 2030 configured to fit within a drivecavity, or receptacle, 2023 of the primary body portion 2010. Theprimary body portion 2010 comprises an upper portion 2011 comprising ajaw-engaging flange 2012. The upper portion 2011 further comprises adistal nose 2013, which can be used to clamp a jaw from an unclampedposition. The primary body portion 2010 comprises a drive surface 2014configured to push a sled and/or a cutting member, for example. Theprimary body portion 2010 further comprises a lower portion 2015comprising a proximal portion 2016 and a distal portion 2019 definingthe drive cavity 2023. The proximal portion 2016 comprises a proximallower flange 2018 extending laterally therefrom and a drive screw duct2017. The distal portion 2019 comprises a distal lower flange 2021 and adrive screw duct 2020. The drive screw ducts 2017, 2020 are aligned witheach other are configured to receive a firing drive screw therethrough;however, the drive screw ducts 2017, 2020 are not threadably coupledwith the drive screw. Rather, the drive screw ducts 2017, 2020 cancomprise support channels, for example, configured to support the firingdrive screw (e.g. firing screw 261 in FIGS. 4 and 5) threadably coupledwith the firing member assembly 2000.

The drive nut 2030 is configured to be threadably coupled with a firingdrive screw and is configured to apply actuation forces to the primarybody portion 2010. The drive nut 2030 is configured to fit within thedrive cavity 2023. The drive nut 2030 comprises a lower threaded portion2035 comprising a camming flange 2031 configured to engage a jaw of anend effector, a threaded channel 2037 configured to be threadablycoupled with a firing drive screw, and a proximal protrusion 2036configured to fit within the drive cavity 2023. The drive nut 2030further comprises an upper drive portion 2040 extending upwardly fromthe threaded portion 2035. The drive portion 2040 comprises a proximaldrive surface 2041 and a distal drive surface 2043. The proximal drivesurface 2041 is configured to push on a proximal drive surface 2025 ofthe drive cavity 2023 when the firing member assembly 2000 is movedproximally and the distal drive surface 2043 is configured to push on adistal drive surface 2024 of the drive cavity 2023 when the firingmember assembly 2000 is moved distally.

As can be seen in FIG. 49, the drive nut 2030 is configured to apply adrive force DF to the primary body portion 2010 off center with respectto a longitudinal screw axis SA. The longitudinal screw axis SA isdefined by a longitudinal centerline though a drive screw configured toactuate the firing member assembly 2000. The longitudinal screw axis SAmay also be synonymous with a longitudinal centerline defined throughthe ducts 2017, 2020.

In at least one instance, the drive nut 2030 comprises a substantiallysimilar cross-sectional profile to the primary body portion 2010. Thedrive portion 2040 is configured to apply an axial drive force to theprimary body portion 2010 away from and/or off-axis with respect to thefiring drive screw and threads 2037.

FIGS. 50 and 51 depict a firing member assembly 2100 comprising theprimary body portion 2010 of the firing member assembly 2000 and a drivenut 2130. The firing member assembly 2100 is similar to the firingmember assembly 2000 except for the drive nut 2100. The drive nut 2100is configured to fit within the drive cavity 2023 of the primary bodyportion 2010. Unlike the drive nut 2030, the drive nut 2130 does notinclude a proximal protrusion. The drive nut 2130 comprises a lowerthreaded portion 2135 comprising a camming flange 2131 configured toengage a jaw of an end effector and a threaded channel 2137 configuredto be threadably coupled with a firing drive screw. The drive nut 2130further comprises an upper drive portion 2140 extending upwardly fromthe threaded portion 2135. The drive portion 2140 comprises a proximaldrive surface 2141 and a distal drive surface 2143. The proximal drivesurface 2141 is configured to push on the proximal drive surface 2025 ofthe drive cavity 2023 when the firing member assembly is movedproximally and the distal drive surface 2043 is configured to push onthe distal drive surface 2024 of the drive cavity 2023 when the firingmember assembly is moved distally. The drive portion 2140 also comprisesan upper surface 2145. The upper surface 2145 does not abut the primarybody portion 2010 within the drive cavity 2023. Embodiments areenvisioned where the upper surface 2145 abuts the primary body portion2010 within the drive cavity 2023. In at least one instance, the flange2131 is configured to prevent the drive nut 2130 from rotating with thefiring drive screw during actuation.

FIG. 52 depicts a firing member assembly 2200 comprising the primarybody portion 2010 of the firing member assembly 2000 and the drive nut2130. The firing member assembly 2100 is similar to the firing memberassembly 2100 except for welds 2251, 2253, 2255. Unlike the firingmember assembly 2100, the welds 2251, 2253, 2255 provide positiveattachment mechanisms within the drive cavity 2023 to attach the drivenut 2130 to the primary body portion 2010. Stated differently, the drivenut 2130 is welded to the primary body portion 2010. Welding can takeplace after the drive nut 2130 is positioned within the drive cavity2023 and threaded to a firing drive screw. The threaded portion 2135 ofthe drive nut 2130 is welded to the proximal portion 2016 of the primarybody portion 2010 and the distal portion 2019 of the primary bodyportion 2010. The upper surface 2045 of the drive portion 2140 is alsowelded to the primary body portion 2010. These welds can providestrength to the firing member assembly 2200.

FIGS. 53-56 depict a stapling assembly 2300 comprising a channel jaw2310, a firing drive screw, or rotary drive member, 2320 comprisingthreads 2321, and a firing member assembly 2330. The firing memberassembly 2330 is similar to the firing member assemblies discussedabove; however, the firing member assembly 2330 comprises a differentdrive nut and attachment means for attaching the drive nut to theprimary body portion. As can be seen in FIG. 53, the firing memberassembly 2330 is threadably coupled to the threads 2321 of the firingdrive screw 2320. The firing drive screw 2320 is configured to besupported within the channel jaw 2310. The firing member assembly 2330is configured to be actuated proximally and distally through a firingstroke relative to the channel jaw 2310.

The firing member assembly 2330 comprises a primary body portion 2331and a drive nut 2360 configured to fit within a drive cavity, orreceptacle, 2343 of the primary body portion 2331. The primary bodyportion 2331 comprises an upper portion 2332 comprising ananvil-engaging flange 2333. The upper portion 2332 further comprises adistal nose 2334 which can be used to clamp an anvil jaw from anunclamped position. The primary body portion 2331 comprises a drivesurface 2335 configured to push a sled and/or a cutting member, forexample. The primary body portion 2331 further comprises a lower portion2336 comprising a proximal portion 2337 and a distal portion 2339defining the drive cavity 2343. The proximal portion 2337 comprises aproximal lower flange 2338 extending laterally therefrom and a drivescrew duct. The distal portion 2339 comprises a distal lower flange 2341and a drive screw duct 2340. The flanges 2338, 2341 are configured toengage the channel jaw 2310 to affirmatively hold a consistent tissuegap between an anvil jaw and the channel jaw 2310. The drive screw ductof the proximal portion 2337 and the drive screw duct 2340 are alignedwith each other and are configured to non-threadably receive the firingdrive screw 2320 therethrough.

The drive nut 2360 comprises a threaded portion 2365 configured to bethreadably coupled with the firing drive screw 2320 by way of threads2366, and a drive portion 2070. The drive nut 2360 further comprises alower camming flange 2361 also configured to cammingly engage thechannel jaw 2310 during a firing stroke. The drive portion 2370comprises laterally opposing tabs 2371 extending upwardly from thethreaded portion 2365. The drive tabs 2371 are configured to cradle, orstraddle, a corresponding drive tab 2350 extending downwardly from theprimary body portion 2331 and into the drive cavity 2343. The driveportion 2370 further comprises an internal cross member, or brace, 2372connecting the tabs 2371 to each other and securing, or attaching, thedrive portion 2370 to the drive tab 2350 and, thus, the primary bodyportion 2331. The cross member 2372 is configured to be received withina drive slot 2351 defined in the drive tab 2350. As the drive nut 2360is actuated, forces can be applied to the primary body portion 2331 fromthe cross member 2372 to the drive tab 2350 within the slot 2351. Such aconfiguration can provide a drive force to the primary body portion 2331off center with respect to the drive screw 2320 and nearer the center ofthe firing member assembly 2330. Stated another way, the drive nut 2360can apply a drive force eccentrically with respect to a longitudinalaxis of the drive screw 2320 to the primary body portion 2331. This canbe seen in FIG. 53, for example. The drive nut 2360 can apply driveforce DF to the primary body portion 2310 off center with respect tolongitudinal screw axis SA.

The drive tab 2350 further comprises a pair of drive teeth 2353extending downwardly therefrom within an internal channel 2367 definedin the drive nut 2360. The drive teeth 2353 are configured to mate withthe threads 2321 of the drive screw 2320 directly. The teeth 2353 maybolster the threaded engagement of the firing drive screw 2320 and thefiring member assembly 2330 as a whole.

In at least one instance, the drive nut 2360 is insert molded over thedrive screw 2320. This permits complex shapes of a drive nut and allowsfor finely tuned engagement features between the drive nut 2360 and theprimary body portion 2331. Such an engagement feature comprises thecross member 2372, for example. Once molded over the drive screw 2320and through the slot 2351, the drive nut 2360 is permanently fixed tothe primary body portion 2331 notwithstanding destroying the drive nut2360 to remove the drive nut 2360 from the primary body portion 2331.

In at least one instance, the drive nut 2360 is snapped to the drive tab2350. For example, the drive nut 2360 may comprise a degree offlexibility and a manufactured split, or break, in the materialcorresponding to the internal channel 2367 permitting the drive nut 2360to be spread around the drive tab 2350 and snapped thereto. In at leastone instance, the drive nut 2360 is separated between a drive tab 2350and one side of the cross member 2372 such that the drive tabs 2359 maybe pried apart to position the cross member 2372 into the slot 2351.

In at least one instance, the cross member 2372 is configured to shearoff of the drive nut 2360 if a firing force between the drive screw 2320and the drive nut 2360 exceeds a predetermined threshold. Such aconfiguration can provide a safety feature so as to not over drive afiring member assembly through a firing stroke when a firing memberassembly experiences a higher than normal load.

FIGS. 57-61 depict a firing member assembly 2400. The firing memberassembly 2400 is similar to the firing member assemblies discussedabove; however, the firing member assembly 2400 comprises a differentdrive nut and attachment means for attaching the drive nut to theprimary body portion. The firing member assembly 2400 also comprisesregistration features for use with a molding tool. The firing memberassembly 2400 is configured to be threadably coupled to a firing drivescrew and is configured to be actuated proximally and distally through afiring stroke by way of the firing drive screw.

The firing member assembly 2400 comprises a primary body portion, ordistal head, 2410 and a drive nut 2450 configured to fit within a drivecavity, or receptacle, 2430 of the primary body portion 2410. Theprimary body portion 2410 comprises an upper portion 2411 comprising ajaw-engaging flange 2412. The upper portion 2411 further comprises adistal nose 2413 which can be used to clamp an anvil jaw from anunclamped position. The primary body portion 2410 further comprises adrive surface 2414 configured to push a sled and/or a cutting member,for example. The primary body portion 2410 further comprises a lowerportion 2415 comprising a proximal portion 2416 and a distal portion2420 defining the drive cavity 2430. The proximal portion 2416 comprisesa proximal lower flange 2417 extending laterally therefrom and a drivescrew duct 2418. The distal portion 2420 comprises a distal lower flange2421 and a drive screw duct 2422. The flanges 2417, 2421 are configuredto engage a jaw of an end effector to affirmatively hold a consistenttissue gap between the jaw and another jaw of the end effector. Thedrive screw ducts 2418, 2422 are aligned with each other are configuredto non-threadably receive the firing drive screw therethrough. Discussedin greater detail below, the proximal portion 2416 and the distalportion 2420 each comprise registration apertures 2423 configured foruse during an overmolding and/or insert molding process.

The drive nut 2450 comprises a threaded portion, or driven portion, 2451configured to be threadably coupled with a firing drive screw by way ofthreads 2453 and comprises a drive portion, or driving portion, 2460.The drive nut 2450 further comprises a lower camming flange 2452 alsoconfigured to cammingly engage an end effector jaw during a firingstroke. The drive nut 2450 comprises a substantially trapezoidal shape.Discussed in greater detail below, the firing member assembly 2400comprises a proximal clearance void, or longitudinal space, 2431 definedbetween the proximal portion 2416 and a proximal drive surface 2454 ofthe threaded portion 2451 and a distal clearance void, or longitudinalspace, 2455 defined between the distal portion 2420 and a distal drivesurface 2455 of the threaded portion 2451.

The drive portion 2460 comprises laterally opposing tabs 2461 extendingupwardly from the threaded portion 2451. It should be appreciated thatthe primary body portion 2410 and the drive nut 2450 is symmetricalrelative to vertical plane defined by the primary body portion 2410 butfor the threads 2453. The drive tabs 2461 are configured to cradle, orstraddle, a corresponding drive tab 2440 extending downwardly from theprimary body portion 2410 and into an upper portion 2433 of the drivecavity 2430. The drive portion 2060 further comprises a plurality ofinternal cross members, or ribs, 2463 extending between the tabs 2461.The ribs 2463 secure, or attach, the drive portion 2460 to the drive tab2440 and, thus, the primary body portion 2410. The ribs 2463 areconfigured to be received within a plurality of corresponding apertures2441 defined in the drive tab 2440. As the drive nut 2450 is actuated,force can be applied to the primary body portion 2410 from the ribs 2463to the drive tab 2440 within the slots 2441. Such a configuration canprovide a drive force to the primary body portion 2331 off center withrespect to the drive screw positioned within the threaded channel 2453and nearer the center of the firing member assembly 2400. As can be seenin FIGS. 57 and 60, the drive nut 2450 can apply a drive force DF to theprimary body portion 2410 off center with respect to a longitudinalscrew axis SA.

The tabs 2461 of the drive nut 2450 are further configured to applyforce to the primary body portion 2410 within the upper portion 2433 ofthe drive cavity 2430 to proximal drive surface 2443 and distal drivesurface 2445. These additional drive surfaces can further center theapplication of drive force to the primary body portion 2410 nearer thecenter of the firing member assembly 2400.

As discussed above, the firing member assembly 2400 comprises clearancevoids 2431, 2432 positioned between the threaded portion 2451 of thedrive nut 2450 and the proximal and distal portions 2416, 2420 of theprimary body portion 2410. The clearance voids are configured to furthercenter the application of drive force within the firing member assembly2400 from the drive nut 2450 to the primary body portion 2410. Theclearance voids 2431, 2432 prevent the threaded portion 2451 fromcontacting the proximal and distal portions 2416, 2420 of the primarybody portion 2410 thereby preventing the application of drive forceimmediately adjacent the drive screw configured to drive the firingmember assembly 2400.

The clearance voids 2431, 2432 can also be configured to control overalldeflection of the drive nut 2450. In various instances, a firing drivescrew can deflect relative to the end effector in which it ispositioned. This can be attributed to clamping forces applied to thejaws of an end effector during a firing stroke, among other things.Notably, as the drive screw deflects, the drive nut 2450 will be urgedto deflect, or rotate, relative to the primary body portion 2410, alongwith the drive screw owing to the threaded engagement between the drivenut 2450 and the firing drive screw. The trapezoidal shape and clearancevoids 2431, 2432 provide a degree of flexibility, or forgiveness, forthe drive nut 2450 to deflect and rotate with the firing drive screw.Permitting this forgiveness within the firing member assembly 2400 canhelp prevent binding of the threaded engagement between the drive nut2450 and the firing screw. A rigid firing assembly and drive nutcombination, for example, may afford little to no flexibility furtherincreasing the likelihood of thread binding, for example. In certaincases, other components of the firing member assembly such as cammingflanges and/or the driving cross members discussed above may elasticallydeform owing to bending and/or shearing forces within an end effectorassembly. In at least one instance, the drive cavity 2430 comprises atrapezoidal shape in addition to or in lieu of the drive nut 2450.

In at least one instance, the drive nut 2450 is insert molded over adrive screw. This permits complex shapes of a drive nut and allows forfinely tuned engagement features between the drive nut 2450 and theprimary body portion 2410. Such an engagement feature comprises the ribs2463, for example. In at least one instance, the drive nut 2450 isovermolded onto the primary body portion 2410.

As discussed above, the proximal portion 2416 and the distal portion2420 each comprise registration apertures 2419, 2423 configured for useduring an overmolding and/or insert molding process. The registrationapertures 2419, 2423 are configured to hold the primary body portion2410 within a molding tool and are aligned at the equator, or center, ofthe ducts 2418, 2020. This positioning can help align the mold used forthe drive nut 2450 with the ducts 2418, 2020 for manufacturing so thatthe drive nut 2450 and, specifically, the threaded portion 2451 isaligned with the ducts 2418, 2020. This alignment ensures that a firingdrive screw is aligned within the ducts 2018, 2020 and the threadedportion 2451 upon assembly. In at least one instance, a firing drivescrew and the primary body portion 2410 are both presented prior tomolding the drive nut 2450. In such an instance, the drive nut 2450 canbe molded around the pre-placed primary body portion 2410 and firingdrive screw. In at least one instance, only the primary body portion2410 is presented prior to molding the drive nut 2450.

FIGS. 62-66 depict a firing member assembly 2500. The firing memberassembly 2500 is similar to the firing member assemblies discussedabove; however, the firing member assembly 2500 comprises a drive nutassembly comprising an external drive portion 2550 and an internal drivenut 2560 positioned within the external drive portion 2550. The firingmember assembly 2500 is configured to be threadably coupled to a firingdrive screw and is configured to be actuated proximally and distallythrough a firing stroke by way of the firing drive screw within an endeffector assembly.

The firing member assembly 2500 comprises a primary body portion 2510and a drive nut assembly configured to fit within a drive cavity, orreceptacle, 2530 of the primary body portion 25510. The primary bodyportion 2510 comprises an upper portion 2511 comprising ananvil-engaging flange 2512. The upper portion 2511 further comprises adistal nose 2513 which can be used to clamp an anvil jaw from anunclamped position. The primary body portion 2510 further comprises adrive surface 2514 configured to push a sled and/or a cutting member,for example. The primary body portion 2510 further comprises a lowerportion 2515 comprising a proximal portion 2516 and a distal portion2520 defining the drive cavity 2530. The proximal portion 2516 comprisesa proximal lower flange 2517 extending laterally therefrom and a drivescrew duct 2518. The distal portion 2520 comprises a distal lower flange2521 and a drive screw duct 2522. The flanges 2517, 2521 are configuredto engage a jaw of an end effector to affirmatively hold a consistenttissue gap between the jaw and another jaw of the end effector. Thedrive screw ducts 2518, 2522 are aligned with each other are configuredto non-threadably receive the firing drive screw therethrough.

As discussed above, the drive nut assembly comprises the external driveportion 2550 and the internal drive nut 2560 positioned within theexternal drive portion 2550. In at least one instance, the internaldrive nut 2560 comprises a stock drive nut comprised of a metallicmaterial, for example. In at least one instance, the external driveportion 2550 comprises of a polymer, for example, and is overmoldedand/or insert molded within the firing member assembly 2500. In such aninstance, the drive nut assembly comprises a hybrid multi-material drivenut assembly and may have metamaterial properties in certain instances.In at least one instance, the external drive portion 2560 is insertmolded to the internal drive nut 2550 and then the drive nut assembly ispositioned within the drive cavity 2530 for assembly to a firing drivescrew and the primary body portion 2510. Regardless, the drive nutassembly comprises a multi-piece arrangement.

The external drive portion 2550 comprises a lower portion 2551comprising a flange 2552. The lower portion 2551 is configured tosurround and secure the internal drive nut 2560 within the drive nutassembly. The external drive portion 2550 further comprises a drive tab2553 positioned within an upper portion of the drive cavity 2530. Thedrive cavity 2530 further comprises a clearance slot 2531 positionedbetween the drive tab 2553 and the primary body portion 2510. Such aclearance slot 2531 can permit the drive nut assembly to float with thefiring drive screw relative to the primary body portion 2510. In such aninstance, the primary body portion 2510 can be constrained by variouselements of an end effector assembly such as, for example, an anvil jawand a channel jaw.

As discussed above, the external drive portion 2550 is configured tosecure the internal drive nut 2560 therein and in line with a screw axisSA. The screw axis SA is defined as the center of the ducts 2518, 2522and a primary cylindrical portion 2561 of the internal drive nut 2560.Threads 2562 are defined in the primary cylindrical portion 2561 of theinternal drive nut 2560. The threads 2562 are configured to bethreadably engaged, or coupled, with threads of a firing drive screw.The internal drive nut 2560 further comprises rows 2563 of grippingfeatures 2564 configured to prevent rotation of the internal drive nut2560 relative to the external drive portion 2550 during drive screwrotation. The external drive portion 2550 can envelop the internal drivenut 2560 during the molding process. The internal drive nut 2560 furthercomprises a flared proximal end 2565. The flared proximal end 2565 canaid assembly of the firing member assembly 2500 with a firing drivescrew. For example, a firing drive screw can be inserted in through theduct 2518 and guided into the threads 2562 of the internal drive nut2560 by the flared proximal end 2565.

In at least one instance, the gripping features 2564 can aid in themanufacturing process of the drive nut assembly. For example, thegripping features 2564 may fit into corresponding slots of a moldconfigured to hold the drive nut 2560 during molding of the externaldrive portion 2550.

FIG. 67 depicts a firing member assembly 2600. The firing assembly 2600is similar to the firing member assemblies discussed above; however, thefiring member assembly 2600 comprises a proximal tail extensionconfigured to further support the firing member assembly 2600 through afiring stroke. The firing member assembly 2600 is configured to bethreadably coupled to a firing drive screw and is configured to beactuated proximally and distally through the firing stroke by way of thefiring drive screw within an end effector assembly.

The firing member assembly 2600 comprises a primary body portion 2610and a drive nut 2630. The primary body portion 2610 comprises an upperportion 2611 and a lower portion 2615. The upper portion 2611 comprisesan anvil-camming flange 2612. The upper portion 2611 further comprises adistal nose 2613 configured to close a jaw of an end effector from anopen position to a closed position. The primary body portion 2610further comprises a drive surface 2614 configured to push a sled and/ora cutting member, for example. The lower portion 2615 comprises aproximal portion 2616 comprising a proximal lower flange 2617 and aproximal tail extension 2618. The lower portion 2615 further comprises adistal portion 2620 comprising a distal lower flange 2621. The flanges2617, 2621, 2612 can be configured to maintain a predefined tissue gapbetween a staple cartridge and an anvil throughout a firing stroke ofthe firing member assembly 2600.

The proximal tail extension 2618 is an extension of a screw duct, suchas those described above, of the proximal portion 2616. Such a proximaltail extension can further support the firing member assembly 2500through a firing stroke. Such a proximal tail extension may also resistdeflection, or rotation, of the primary body portion 2610 which maycause a threaded engagement between the drive nut 2630 and the firingdrive screw to bind.

FIGS. 68-72 depicts a firing member assembly 2700 threadably coupledwith a firing drive screw 2701. The firing assembly 2700 is similar tothe firing member assemblies discussed above; however, the firing memberassembly 2700 comprises a primary body portion 2710 and a drive nut 2750snappable to the primary body portion 2710. The firing member assembly2700 is configured to be actuated proximally and distally through afiring stroke by way of the firing drive screw 2701 within an endeffector assembly.

The primary body portion 2710 comprises an upper portion 2711 and alower portion 2715 defining a drive cavity 2730. The drive nut 2750 isconfigured to be positioned within the drive cavity 2730. The upperportion 2711 comprises a jaw-camming flange 2712. The upper portion 2711further comprises a distal nose 2713 configured to close a jaw of an endeffector from an open position to a closed position. The primary bodyportion 2710 further comprises a drive surface 2714 configured to push asled, for example. The lower portion 2715 comprises a proximal portion2716 comprising a proximal lower flange 2717. The lower portion 2715further comprises a distal portion 27720 comprising a distal lowerflange 2721 and a drive screw duct 2722 defined therein configured tonon-threadably receive the firing drive screw 2701. The flanges 2617,2721, 2712 can be configured to maintain a predefined tissue gap betweena staple cartridge and an anvil throughout a firing stroke of the firingmember assembly 2700.

In at least one instance, a profile or perimeter of the drive screw duct2722 and/or a proximal portion of the drive screw duct can be ovalshaped and/or oblong or, non-circular, for example. Such a configurationcan reduce the likelihood of a deflected drive screw rubbing orinterfering inside the screw ducts, which can cause stack-up losses inthe event of such drive screw deflection. Stack-up losses can refer tothe various problematic engagements of the drive screw and othercomponents within the system that would result in various interferencesin a scenario where the drive screw is deflected substantially. Forexample, if a drive screw is deflected substantially, the deflecteddrive screw, as discussed above, may rub against a drive screw duct, thedeflected drive screw may cause the threads of a drive nut to bind,and/or the deflected drive screw may bind near its connection with afiring output shaft, for example. Providing features to minimize suchstack-up losses can prevent premature failure of components and/orreduce the firing forces necessary to drive a firing member assembly,for example.

In at least one instance, the drive screw duct 2722 and/or a proximalportion of the drive screw duct comprises filleted or chamfered edges.Such a configuration can further reduce the likelihood of the ductscontacting and binding with the firing drive screw.

In at least one instance, a screw duct of a primary body portion canprovide lateral and/or vertical support to the drive screw such that,should the drive screw be loaded enough to induce bending of the drivescrew, the drive screw duct can prevent the drive screw from bending atleast near the threaded drive nut. Such a configuration can help preventbinding between the threads of the drive screw and the threaded drivenut.

In at least one instance, a sled of a staple cartridge can comprise adistally extending cradle support feature extending from a distal end ofthe sled. The cradle support feature may also support the firing drivescrew and help prevent bending of the firing drive screw at least nearthe cradle support feature. In at least one instance, the sled preventsbending of the drive screw in only one direction. In at least oneinstance, the sled comprises a proximal cradle support feature inaddition to or in lieu of the distal cradle support feature.

The drive nut 2750 comprises a jaw-engaging flange 2751, a threadedportion 2755 configured to be threadably coupled with the firing drivescrew 2701 by way of threads 2756, and laterally-opposing drive tabs2760 extending upwardly from the threaded portion 2755. The drive nut2750 comprises a substantially trapezoidal shape such as those drivenuts comprising a trapezoidal shape discussed herein.

The drive tabs 2760 are configured to cradle, or straddle, acorresponding drive tab 2740 extending downwardly from the primary bodyportion 2710. The drive tabs 2760 define a slot 2761 therebetween andeach comprise a snap nub 2762 protruding inwardly therefrom. The snapnubs 2762 each comprise a sloped upper surface 2763 and a latch surface2764. As can be seen in FIG. 71, the drive tabs 2760 are configured tosnap to the drive tab 2740 of the primary body portion 2710.Specifically, the drive tab 2740 comprises a horizontally extending slot2741 defined therein and the snap nubs 2762 are configured to widen thedrive tabs 2760 during installation of the drive nut 2750 with theprimary body portion 2710 enough such that the latch surfaces 2764 clearthe drive tab 2740 and can bias inwardly into the slot 2741. In at leastone instance, the snap nubs 2762 are not configured to transfer anylongitudinal drive forces from the firing drive screw 2701 to theprimary body portion 2710. Instead, the drive tabs 2760 are configuredto fit within the drive cavity 2730 such that the drive tabs 2760directly push and pull the primary body portion 2710 relative to thefiring drive screw similar to various firing member assemblies discussedherein. Such a configuration can alleviate the reliance on the internalcross members of the drive nut 2750 to transfer firing force from thefiring drive screw 2701 to the primary body portion 2710. This can beadvantageous in that the drive nut 2750 can remain attached to theprimary body portion 2710 through the drive nubs 2762 through higherthan normal loads. Like various drive tabs discussed herein, the drivetabs 2760 of the drive nut 2750 are further configured to apply force tothe primary body portion 2710 nearer the center of the primary bodyportion 2710. As can be seen in FIG. 69, the drive nut 2750 isconfigured to apply a drive force DF to the primary body portion 2710off axis with respect to a longitudinal screw axis SA.

In at least one instance, the drive nut 2750 is injection molded priorto being snapped onto the primary body portion 2710. In at least oneinstance, the drive nut 2750 is insert molded onto the primary bodyportion 2710 and the firing drive screw 2701. In such an instance, thedrive nut 2750 may be snapped off and replaced should the drive nut 2750wear out over time, for example.

FIG. 73 depicts a firing member assembly 2800 comprising a primary bodyportion 2810 and a drive nut 2850 configured to be threadably coupled toa firing drive screw. The firing member assembly 2800 is similar tovarious firing member assemblies discussed above; however, the firingmember assembly 2800 further comprises a drive cavity 2830 configured topermit the primary body portion 2810 to flex during a firing drivestroke as discussed in greater detail below.

The primary body portion 2810 comprises an upper portion 2811 comprisinga flange 2812 extending laterally therefrom and a distal nose 2813configured to close a jaw from an open position during a closure stroke.The primary body portion 2810 further comprises a drive surface 2814configured to push a sled and/or a cutting member through a staplefiring stroke, for example. Other embodiments are envisioned wherevarious other surfaces on the front of the primary body portion 2810 areconfigured to drive various components such as a sled and/or a cuttingmember, for example. The primary body portion 2810 further comprises alower portion 2815 comprising a proximal portion 2816 comprising aproximal lower flange 2817 and a distal portion 2820 comprising a distallower flange 2821. Collectively, the flanges 2812, 2817, 2821 areconfigured to affirmatively space opposing jaws during a firing strokeand maintain a consistent tissue gap between the opposing jaws.

The drive nut 2850 is positioned within the drive cavity 2830 and isconfigured to be threadably coupled to a firing drive screw. The drivenut 2850 is configured to apply axial drive forces to the primary bodyportion 2810 as the firing drive screw is actuated to move the firingmember assembly 2810 proximally and distally within an end effector. Thedrive cavity 2830 comprises a lower portion 2833 where the drive nut2850 is primarily positioned and is configured to float within andcomprises an upper triangular portion 2831. The upper triangular portion2831 is configured to permit the primary body portion 2810 to flexduring a firing stroke. For example, under clamping loads, thetriangular portion 2831 is configured to permit the proximal portion2816 to flex longitudinally away from the distal portion 2820. Suchflexion can provide forgiveness within the firing member assembly 2800so as to prevent binding, for example. In addition to flexion of theprimary body portion 2810, the drive nut 2850 is configured to floatwithin the drive cavity 2850. Collectively, such an arrangement canreduce binding engagement between the threaded connections and/orbinding engagement between the flanges and jaws.

Various drive nuts disclosed herein comprise a laterally extendingflange aligned with the proximal and distal lower flanges of the lowerportions of the primary body portions. Such a flange can prevent thedrive nut from rotating with a firing drive screw. Such a flange cancomprise a rounded bottom so as to reduce binding engagement with acorresponding jaw. For example, the proximal and distal lower flangescan be configured to handle the majority of the clamping loads while thedrive nut flange is provided for support to the drive nut but notnecessarily to handle high clamping loads. Rounding the flange canreduce the overall contact with the corresponding jaw thus reducing thelikelihood of the flange from binding against the corresponding jaw. Insuch an instance, the flange, or lateral fin, of the drive nut isconfigured to be loose within the corresponding jaw, such as a channeljaw, for example. This loose engagement between the flange and thecorresponding jaw can provide the anti-rotation feature withoutrequiring the flange to handle high clamping loads. In at least oneinstance, the lateral fin is overall thinner and comprises a top edgewhich is positioned below top edges of corresponding proximal and distallower flanges of a primary body portion.

In at least one instance, the primary body portions are machined from ametallic material and the drive nuts are injection molded, insertmolded, or overmolded from a polymer and/or a plastic material. Such aconfiguration can reduce manufacturing costs and machining complexity asvarious molding processes can allow for more complex geometries andshapes. Various molding processes can also allow for various order ofcomponent assembly and manufacturing. As discussed above, insert moldingallows the multi-material firing member assembly to comprise variousmaterials as well as complex integrated geometries between the differentmaterials. Moreover, insert molding, for example, permits the firingdrive screw to be positioned within the firing member assembly prior tomolding of the drive nut.

FIGS. 74-78 depict an end effector assembly 3000 configured to cut andstaple the tissue of a patient. The end effector assembly 3000 comprisesa first jaw 3010 and a second jaw 3020 movable relative to the first jaw3010. Embodiments are envisioned where the first jaw 3010 is movablerelative to the second jaw 3020. The first jaw 3010 comprises acartridge channel 3100 and a replaceable staple cartridge 3300configured to be removably positioned within the cartridge channel 3100.The second jaw 3020 comprises an anvil 3200 configured to deform staplesremovably stored in the staple cartridge 3300 during a staple firingstroke. The second jaw 3020 is movable, or pivotable, relative to thefirst jaw 3010 to clamp tissue between the anvil 3200 and the staplecartridge 3300. Once tissue is clamped between the anvil 3200 and thestaple cartridge 3300, the end effector assembly 3000 is fired to ejectstaples and cut tissue with a firing assembly 3400 of the end effectorassembly 3000.

Discussed in greater detail below, the firing assembly 3400 comprises afiring drive screw 3401 supported within the cartridge channel 3100. Thefiring assembly 3400 further comprises a firing member assembly 3409threadably coupled to the firing drive screw 3401 which is configured topush a sled to deploy staples from the staple cartridge 3300 during afiring stroke, push a cutting member to cut tissue during the firingstroke, and maintain a consistent tissue gap between the staplecartridge 3300 and the anvil 3200 during the firing stroke.

The cartridge channel 3100 comprises a longitudinal channel cavity 3111within which the staple cartridge 3300 is removably positioned. Thecartridge channel 3100 also comprises side walls 3113 configured tosupport the staple cartridge 3300. In at least one instance, the staplecartridge comprises ledges configured to rest on top of the side walls3113. The cartridge channel 3100 further comprises a base portion 3120.The base portion 3120 comprises an internal bottom surface 3121 andcamming ledges 3123. A longitudinal slot 3125 is defined between thecamming ledges 3123 and is configured to receive at least a portion ofthe firing assembly 3400 therethrough.

The anvil 3200 comprises a body portion 3210 and an anvil cap 3220configured to be attached to the body portion 3210 within a longitudinalchannel 3212. The body portion 3210 comprises an anvil surface 3211. Theanvil surface 3211 comprises a plurality of staple forming pocketsaligned with staple cavities 3312 defined in a deck 3311 of staplecartridge body 3310. The body portion 3210 also comprises camming ledges3213 extending laterally inwardly into the longitudinal channel 3212 anddefining a longitudinal slot 3225 therebetween. Discussed in greaterdetail below, the camming ledges 3123, 3213 are configured to becooperatively engaged by corresponding flanges of the firing memberassembly 3409 to affirmatively space the jaws 3010, 3020 relative toeach other. In at least one instance, a predefined tissue gap is definedbetween the cartridge deck 3311 and the anvil surface 3211 during afiring stroke by way of the engagement of the flanges of the firingmember assembly 3409 with the camming ledges 3213, 3123.

The staple cartridge 3300 further comprises deck protrusions, or pocketextenders, 3314 configured to extend the effective height of each staplecavity 3312. The deck protrusions 3314 can be configured to help griptissue clamped between the jaws 3010, 3020. The staple cartridge 3300further comprises a longitudinal slot 3315 configured to receive atleast a portion of the firing member assembly 3409 therethrough. Asdiscussed above, a sled and/or cutting member is configured to beadvanced through the jaws 3010, 3020 to cut tissue and fire staplesduring a staple firing stroke with the firing assembly 4400.

The firing assembly 3400 comprises the firing drive screw 3401 and thefiring member assembly 3409 threadably coupled to the firing drive screw3401. The firing member assembly 3409 comprises a primary body portion3410, a drive nut 3450 configured to be threadably coupled to the firingdrive screw 3401, and a rear support brace 3430. The primary bodyportion 3410 comprises an upper portion 3411 comprising ananvil-engaging flange 3412 and a distal nose portion 3413. Theanvil-engaging flange 3412 is configured to move within the longitudinalchannel 3212 and, more specifically, configured to apply clampingpressure to the upper surface 3214 of the camming ledges 3213. In atleast one instance, the anvil cap 3220 is configured to provide an upperboundary to the anvil-camming flange 3412. Nonetheless, theanvil-camming flange 3412 is configured to move within the longitudinalchannel 3212 during a firing stroke to apply camming forces thereto toensure a consistent tissue gap distance between the cartridge deck 3311and the anvil surface 3211.

The primary body portion 3410 further comprises a lower portion 3415comprising a proximal portion 3416 comprising a channel-camming flange3417 and a screw duct 3418 configured to non-threadably receive thefiring drive screw 3401 therethrough. The lower portion 3415 furthercomprises a distal portion 3420 comprising a channel-camming flange 3421and a screw duct 3422 configured to non-threadably receive the firingdrive screw 3401. The drive nut 3450 is configured to fit between theproximal portion 3416 and the distal portion 3420. The drive nut 3450comprises a threaded portion 3451 configured to be threadably coupled tothe firing drive screw 3401 and comprising a channel-camming flange3452. In at least one instance, the channel-camming flange 3452comprises a thickness that is less than the thickness of thechannel-camming flanges 3417, 3421. The drive nut 3450 also comprises adrive tab 3460 extending upwardly toward the primary body portion 3410.The drive nut 3450 is configured to apply axial drive forces proximallyand distally to the primary body portion 3410 to move the firing memberassembly 3409 through jaws 3010, 3020. The channel-camming flanges 3417,3452, 3421 are configured to apply camming forces to the camming ledges3123. Collectively, the camming flange 3412 and the flanges 3417, 3452,3421 are configured to maintain a consistent tissue gap distance betweenthe cartridge deck 3311 and the anvil surface 3211.

Firing member assemblies can be subject to loads which would cause offcenter moment loading. For example, the anvil ledges engaged with uppercamming flanges 3412 can apply an off-center moment load to the firingmember 3400 in certain instances, such as when thick and/or tough tissueis clamped between the jaws. It can be advantageous to provide a meansfor counter-acting such off center moment loading. The firing memberassembly 3409 comprises a rear support brace 3430 extending at an angleproximally from the upper portion 3411 of the primary body portion 3410.The rear support brace 3430 comprises a strut member 3431 and an arcuatebrace portion 3433 extending from the strut member 3431. The arcuatebrace portion 3433 comprises laterally extending flanges 3435 configuredto support the rear support brace 3430 and counteract moment loading ofthe primary body portion 3410. The flanges 3435 are configured to rideagainst the internal bottom surface 3121. Notably, the flanges 3435 rideabove the camming ledges 3123 such that the flanges 3432 of the rearsupport brace 3430 and the channel-camming flanges 3421 contact oppositesides of the base portion 3120 of the channel 3100.

In at least one instance, should the primary body portion 3410 be loadedand cause rotation in an opposite direction, the flanges 3435 mayprovide flexibility to lift off of the internal bottom surface 3121 andresist torqueing of the anvil-camming flanges 3412 out of substantiallyparallel alignment with the longitudinal channel 3214. The rear supportbrace 3430 can be configured to provide a degree of flexibility so as topermit some flexion of the primary body portion 3410 during loadingwhile preventing a magnitude of flexion that would cause binding if thethreaded engagement between the drive nut 3450 and the firing drivescrew 3401. In certain instances, the rear support brace 3430 can act asa spring feature for balancing the load.

Embodiments are envisioned where the flanges 3435 are positioned underthe ledges 3123. Embodiments are also envisioned where two sets offlanges are provided. One set of flanges can be positioned above theledges 3123 and one set of flanges can be positioned below the ledges3123.

In various instances, the rear support brace 3430 acts a spring memberfor the firing member assembly 3409 to balance various loads experiencedby the firing member assembly 3409. Moreover, a clearance is providedbetween the arcuate brace portion 3433 and the firing drive screw 3401.Such a configuration can prevent I-beam roll, for example, and balancean I-beam, or firing member assembly, throughout a staple firing stroke.Embodiments are envisioned where the arcuate brace portion 3433 is alsothreaded and threadably coupled to the firing drive screw 3401.

In various instances, the geometries of various firing member componentscan be optimized. Referring to FIG. 78, for example, the length of acentral portion of the primary body portion 3410 is referred to as thebody length BL and the length of the lower flanges 3417, 3421,collectively, are referred to as the pin length PL. Generally, the pinlength PL is about twice the length of the body length BL. This may alsoapply to the upper flange 3412. However, in certain instances, the upperflange 3412, for example, may comprise a shorter pin length than twicethe body length BL at least because the rear support brace 3430 can helpprevent the upper flange 3412 from rotating and/or deflecting underload. In various instances, the longer the pin length, the more likelythe corresponding flange is will bind within its slot. In suchinstances, the clearance slot within which the flange is positionedshould be smaller so as to reduce binding between the flange and theclearance slot.

FIGS. 79 and 80 depict a surgical stapling assembly 3700 similar tothose discussed above. However, the surgical stapling assembly 3700combines a triangular drive cavity cutout in addition to various otherfeatures discussed herein. The surgical stapling assembly 3700 comprisesa channel jaw 3710, a staple cartridge 3730 configured to be receivedwithin the channel jaw 3710, and a firing drive screw 3711 supportedwithin the channel jaw 3710. The surgical stapling assembly 3700 furthercomprises an anvil jaw 3720 configured to deform staples ejected fromthe staple cartridge 3730. The surgical stapling assembly furthercomprises a firing member assembly 3740 configured to be actuated by thefiring drive screw 3711 through the jaws 3710, 3720. The firing memberassembly 3740 comprises a primary body portion 3741, a rear supportbrace 3745, and a drive nut 3743 threadably coupled to the firing drivescrew 3711. The primary body portion 3741 comprises a triangular drivecavity cutout 3745 configured to provide an additional spring featurewithin the firing member assembly 3740 configured to balance variousloads experienced by the firing member assembly 3740. The surgicalstapling assembly 3700 further comprises a knife 3750 configured to cuttissue during a firing stroke and a sled 3760 configured to deploystaples from the staple cartridge 3730. The knife 3750 and the sled 3760can each experience and transfer loads to the firing member assembly3740.

The knife 3750 is a component of the sled 3760 and is mounted to thesled 3760 at a pivot. During a distal firing motion, the knife 3750 canassume the upright configuration shown in FIG. 79, in which the knife3750 protrudes out of the cartridge body and the cutting edge thereof isconfigured to cut tissue. During a proximal firing motion, the knife3750 can assume a shielded configuration, in which at least a portion ofthe cutting edge of the knife 3750 is shielded by the fastenercartridge. The knife 3750 can pivot between the upright configurationand the shielded configuration in response to the firing directionand/or various mechanical lockouts and/or biasing mechanisms in thestaple cartridge.

FIG. 81 depicts a jaw assembly 3800 configured to support a firing drivescrew 3801 therein. Under high loads, a firing drive screw may tend tobuckle. The jaw assembly 3800 is configured to prevent buckling of thefiring drive screw 3801. The jaw assembly comprises a channel jaw 3810comprising a bottom 3811 and channel walls 3813 extending from thebottom 3811. The bottom 3811 comprises a drive cavity 3815 configured toreceive the firing drive screw 3801 and one or more flanges such as thecamming flanges discussed herein. The bottom 3811 further comprises alower support 3816 and lateral supports 3818 extending from cammingledges 3817. The lower support 3816 and lateral supports 3818 areconfigured to restrain the firing drive screw 3801 from buckling underhigh loads. In at least one instance, the supports 3816, 3818 arepositioned only near the middle of the firing stroke and channel jaw,for example. Such an arrangement may suffice owing to the fact that,under high loads, the firing drive screw 3801 may tend to buckle nearthe center of its effective length. In at least one instance, thesupports 3816, 3818 may be longitudinal ribs that extend along themajority of the length of the firing drive screw 3801 and channel jaw3810. The supports 3818 can comprise of metal arms and act as hard stopsfor the firing drive screw 3801.

In at least one instance, the supports 3818 comprise plastic arms. Insuch an instance, the supports 3818 can be pried out of the way of afiring member assembly by the firing member assembly as the firingmember assembly passes by the supports 3818 during a firing stroke. Sucha configuration can be advantageous at least because once the firingmember assembly reaches the location of the supports 3818 during thefiring stroke, the firing member assembly can then, itself, support thefiring drive screw 3801 and prevent buckling thereof.

In various instances, balancing an I-beam, or firing member assembly,can be advantageous so as to optimize loading of the firing memberassembly between the anvil camming flanges and channel camming flanges,for example. Various forces are applied to the firing member assembly.These forces are applied by the firing drive screw and/or the drive nut,the anvil camming flanges, the channel camming flanges, the tissue,and/or the sled configured to deploy staples. It may be advantageous tobalance these forces such that the driving force provided by the drivescrew is driving the firing member assembly at an optimal location. Aless than optimal driving force application may result in unnecessaryroll, rotation, and/or rocking, of the firing member assembly relativeto the firing screw and/or relative to a longitudinal axis defined bythe firing screw. Torsional loads may cause such roll, rotation, and/orrocking, for example. Applying the drive force at a location tooptimally counteract the predictable torsional loads applied to thefiring member assembly can help prevent the roll, rotation, and/orrocking of the firing member assembly.

In various instances, the channel/anvil camming flanges, or pins,comprise width and length that is configured to be tuned relative totheir corresponding slots through which they are received. In at leastone instance, the greater the length of the flange along thelongitudinal axis, the less clearance is required within itscorresponding camming slot. In other words, the corresponding cammingslot may comprise a geometry to more tightly receive the flange. On theother hand, the lesser the length of the flange along the longitudinalaxis, the greater the clearance required within its correspondingcamming slot. In other words, the corresponding camming slot maycomprise a geometry to more loosely receive the flange. In at least oneinstance, an ideal length of one or more of the flanges may compriseabout twice the width of the primary body portion of the firing memberassembly. Notably, the thickness of the of primary body portion issynonymous with the portion of the primary body portion configured totravel through the longitudinal staple cartridge slot.

In various instances, drive nuts disclosed herein are configured tofloat up and down relative to the primary body portion of the firingmember assembly, up and down and side to side relative to the primarybody portion of the firing member assembly, and/or side to side relativeto the primary body portion of the firing member assembly. The floatingof the drive nut can reduce the likelihood of the drive screw bindingwith various other components. As discussed above, a drive nut may berigidly welded to a primary body portion in certain instances.

In various instances, the various components of the surgical staplingassemblies disclosed herein can be assembled in a particular order so asto prevent inadvertent disassembly. For example, various components canbe introduced during assembly after the firing member assembly isintroduced, which would otherwise tend to fall out or be disassembledinadvertently without a holding force in the assembly provided byflanges of the firing member assembly, for example. Components andsub-assemblies in addition to or other than the firing member assemblymay also provide assembly holding forces, for example. For example, adrive screw can be pre-loaded, as discussed herein, and can provide aninternal assembly holding force during assembly. The drive screw may beinstalled into the surgical stapling assembly prior to various othercomponents. In certain instances, the above-discussed assembly holdingforces could actually encourage inadvertent disassembly of one or morecomponents. In such instances, such components would be installed aftercertain components so as to ensure that, when such components areinstalled, the entire assembly at that point in time can maintain anassembled state so as to reduce the likelihood of inadvertentdisassembly.

In at least one instance, a plastic and/or metal injection molded (MIM)drive nut of a firing member assembly can first be assembled to theprimary body portion of the firing member assembly. Once the drive nutis positioned, then a drive screw can be threaded into the drive nutthrough corresponding ducts of the primary body portion. Assembling insuch a manner allows the drive screw to couple the drive nut and primarybody portion of the firing member assembly so as to prevent inadvertentdisassembly of the drive nut and the primary body portion.

Further to the above, the drive screw ends can then be coupled to theircorresponding supports with their corresponding attachment means. Forexample, any bearings and/or springs used, for example, can all beassembled at this time. This would prevent the firing member assemblyfrom running off of the proximal end or distal end of the drive screw.Additionally, should the firing member assembly be overdriven, forexample, the thrust bearings would already be presented and the firingmember assembly would predictably deflect a channel for example, throughthe thrust bearing and/or channel support flange, for example, ratherthan abnormally loading only the thrust bearing and or distal headportion of the drive screw, for example. If the firing member assemblyis advanced into a thrust bearing and/or distal head portion of thedrive screw, the firing member assembly may exert an unexpected loadonto the thrust bearing and/or distal head portion of the drive screwand possibly cause premature failure of the thrust bearing and/or distalhead portion, for example. This can be attribute to not being assembledto their corresponding channel support flanges, for example, with whichthe ends of the drive screw are designed to interact and cooperativelyload. Without the channel flanges and the channel, for example, a distalhead portion of a drive screw can be sheared off if prematurely loadedprior to the installation of the drive screw into the channel supportflanges, for example.

In at least one instance, a firing member assembly is advanced beyondits distal-most position during actual operation of a surgical staplingassembly on the drive screw so that the flanges of the firing memberassembly can be inserted within their corresponding slots in the anvil,channel, and/or staple cartridge, for example. Once the flanges arealigned with their corresponding slots, the drive screw can be rotatedto move the firing member assembly proximally thereby moving the flangesinto their corresponding slots. As such point, the drive screw can thenbe seated within its support flanges, for example. In at least oneinstance, using such a sequential assembly method can prevent theflanges from coming loose out of their respective slots during assembly,for example.

In at least one instance, the various supports positioned within theproximal end of an end effector assembly are configured to support aproximal end of a firing drive screw and are configured to support aclosure drive screw interlock with a cartridge channel, for example. Insuch an instance, an anvil can be introduced to the end effectorassembly and pinned to the cartridge channel with a pivot pin after thevarious supports are positioned in the cartridge channel. The pivot pin,itself, can prevent vertical decoupling loads from decoupling variouscomponents of the end effector assembly. In such an instance, lateralchannel walls along with lateral tissue stops, lateral walls of theanvil configured to straddle the lateral channel walls upon clampingtissue, can prevent lateral decoupling loads from decoupling variouscomponents of the end effector assembly. In various instances, the endeffector assembly is configured such that each component andsub-assembly is assemble-able and disassemble-able in one uniquesequential manner. This would ensure that the system can be assembled inonly one way which provides support and prevents inadvertent disassemblyduring assembly.

In various instances, one or more components of surgical staplingassemblies discussed herein can be 3D printed. More specifically, suchcomponents can be made using a graphite-based selective laser sinteringprocess, which can be an additive manufacturing process allowing forcomplex geometries of parts while eliminating the need for expensivetooling. Specifically, thrust bearings and/or drive nuts of firingmember assemblies can be manufactured using this process. In variousinstances, a drive nut can be 3D printed out of graphite and steel, forexample. In at least one instance, between about 1% and about 5% of thecomponent comprises graphite and the rest of the component comprises asteel material. In such an instance, the exposed graphite of the drivenut, for example, could provide a degree of lubrication within thethreaded connection, for example.

In various instances, firing member assemblies are configured to bedriven by firing drive screws positioned within an end effector. Thefiring member assemblies and/or the firing drive screws can experiencevarious loads during a firing stroke. For example, a firing memberassembly can experience loads applied thereto by tissue as the firingmember assembly is advanced through a firing stroke. The firing memberassembly can be subject to various loads applied thereto by the firingdrive screw itself. The firing member assembly can also experience loadsgenerated by the engagement of camming flanges of the firing memberassembly with a cartridge channel jaw and/or an anvil jaw. The firingdrive screw can also be subject to various loads during various stagesof use of an end effector assembly within which the screw is positioned.For example, the firing drive screw may be subject to bending loadsowing to camming and/or clamping forces applied within the end effectorassembly when the jaws are closed to clamp tissue and/or when tissue isfurther clamped by flanges of a firing member assembly during a staplefiring stroke. Discussed herein are various arrangements configured tomanage the various loads experienced by firing member assemblies andfiring drive screws. Such arrangements can reduce binding of a firingdrive screw with various components, for example. Such arrangements canalso be employed with a closure drive system. For example, in variousinstances, an end effector assembly can comprise a separate closuredrive screw configured to open and close a jaw relative to another jaw.In such instances, the closure drive screw can also be subject tovarious loads which may cause bending and/or binding with various drivecomponents, for example

FIGS. 82-84 depict a surgical stapling assembly 5000 comprising acartridge channel 5010, a staple cartridge 5050 seated within thecartridge channel 5010, and a rotary drive assembly 5030 supportedwithin the channel 5010. The cartridge channel 5010 comprises a distalportion 5011, a bottom 5020, and sidewalls 5012 extending verticallyfrom the bottom 5020. The bottom 5020 comprises a distal end 5021, anannular cradle slot 5022 defined in the distal end 5021 of the bottom,and a pair of arcuate flanges 5023 extending upwardly from the bottom5020. The arcuate flanges 5023 are configured to floatably support therotary drive assembly 5030. Various features of the distal end 5021comprise a distal mount, for example, of the drive screw 5031.

The rotary drive assembly 5030 comprises a threaded screw portion 5031and a distal end 5033 supported by the distal portion 5011 of thecartridge channel 5010. The distal end 5033 of the rotary drive assembly5030 comprises two thrust bearings, or bushings, 5034 for example,configured to contact the arcuate flanges 5023. The distal end 5033further comprises a distal support head 5035 configured to support thethrust bearings 5034 against the arcuate flanges 5023. The distalsupport head 5035 may be formed using an orbital forming process on adistal end of a firing drive screw, for example. This forming processcan take place, for example, after one or more bushings and/or bearingsare positioned on the distal end of the firing drive screw.

The arcuate flanges 5023 define a float cavity 5025 therebetween in thedistal portion 5011 of the cartridge channel 5010. A portion 5032 of therotary drive assembly 5030 is configured to be supported within thefloat cavity 5025 such that the distal end 5033 of the rotary driveassembly 5030 is permitted to float within the float cavity 5025 upondeflection of the cartridge channel 5010, for example. In such aninstance where the distal portion 5011 of the cartridge channel 5011 isdeflected downwardly, the distal end 5033 of the rotary drive assembly5030 can remain relatively unloaded by floating within the float cavity5025. As can be seen in FIG. 84, the float cavity 5025 comprises avertical slot portion 5026 configured to permit a predefined floatdistance, or vertical limit of floatation, of the drive assembly 5030and/or portion 5032 of the rotary drive assembly 5030. The portion 5032may be limited in its ability to float vertically within the floatcavity 5025 by the flanges 5023, for example.

Embodiments are envisioned where there is no vertical limiting featuredefined by the bottom 5020 of the cartridge channel 5010. In at leastone instance, the annular cradle slot 5022 is configured to support thebushings 5034 and/or the distal support head 5035. In at least oneinstance, the annular cradle slot 5022 defines a lower vertical limitingfeature, or stop, configured to prevent the distal end 5033 of therotary drive assembly 5030 from floating below a certain thresholddefined by contact between the bushings 5034 and/or 5035 with theannular cradle slot 5022, for example. In at least one instance, thevertical slot portion 5026 and the flanges 5023 define an upper verticallimiting feature, or stop, configured to prevent the distal end 5033 ofthe rotary drive assembly 5030 from floating above a certain thresholddefined by contact between the distal end 5033 and the flanges 5023.

As can be seen in FIG. 83, the staple cartridge 5050 comprises a distalnose 5051 defining a nose cavity 5053 therein. The nose cavity 5053 mayprovide space for the distal end 5033 of the rotary drive assembly tofloat within.

In at least one instance, a proximal end of the rotary drive assembly5030 is fixed in place. In at least one instance, the proximal end ofthe rotary drive assembly 5030 is also configured to float relative tothe cartridge channel 5010.

In at least one instance, a spring is provided at a proximal mountinglocation and/or distal mounting location of a firing drive screw withina cartridge channel, for example. The spring is configured to bias thefiring drive screw into a neutral configuration. In at least oneinstance, the spring is configured to counteract bending loads appliedto the firing drive screw. In at least one instance, one or more magnetsare provided within a mounting location and a screw magnet of oppositepolarity is provided on the firing drive screw at the mounting location.Such a configuration can bias the firing drive screw toward a neutralconfiguration as well as counteract bending loads applied to the firingdrive screw. Such a spring may comprise a vertically deformable bushing,for example. In at least one instance, a coil spring is employed withinthe mounting location.

In various instances, the flexible floatation mounts described hereinare configured to permit a limited vertical range of floatation of therotary drive assembly relative to the cartridge channel. For example, avertical floatation range of 0.0002-0.0003 inches can be permitted bythe distal mounts described herein. In other instances, a verticalfloatation range of 0.001 inches can be permitted and, in certaininstances, of up to 0.0015 inches can be permitted by the flexiblefloatation mounts. The size of the vertical floatation range can beconfigured to avoid lateral loads being applied to the rotary driveassembly, which is well-suited for tension loads but may result inbending under lateral loads. Instead, the rotary drive assembly canfloat within the limited vertical range of floatation to ensure therotary drive assembly is not laterally loaded. Even when thick and/ortough tissue is clamped between the jaws and the anvil is bowed in theclamped configuration, the vertical range of floatation can allowshifting of the rotary drive assembly and avoid lateral loads on therotary drive assembly.

In at least one instance, flanges of a firing member assembly areconfigured to define the limited vertical range of floatation of afiring drive screw through the threaded connection between the firingmember assembly and the firing drive screw. For example, ananvil-engaging flange may contact an upper portion of an anvil slotand/or a channel-engaging flange may contact an upper portion of achannel slot to provide an upper stop for the firing drive screw.Further to the above, the anvil-engaging flange may contact a lowerportion of the anvil slot and/or the channel-engaging flange may contacta lower portion of the channel slot to provide a lower stop for thefiring drive screw. In at least one instance, a drive nut cutout, drivecavity, and/or receptacle configured to receive a drive nut isconfigured to further define the vertical range of flotation of a firingdrive screw.

FIG. 85 depicts a surgical stapling assembly 5100 comprising thecartridge channel 5010 of the surgical stapling assembly 5000. Thesurgical stapling assembly 5100 comprises a rotary drive assembly 5130comprising a threaded portion 5131 and a distal end 5133. The distal end5133 comprises one or more bearings 5134 configured to support thedistal end 5133 against the flanges 5023. The distal end 5133 furthercomprises a distal support head 5135 comprising a swaged screw end 5136.The swaged screw end 5136 may be externally swaged and/or internallyswaged. The swaged screw end 5136 is configured to provide a distalbearing surface for the one or more bearings 5134. The rotary driveassembly 5130 is configured to float within the cartridge channel 5010similar to the rotary drive assembly 5030.

Any suitable bushings and/or bearings can be employed with any of thevarious rotary drive assemblies and/or firing drive screws disclosedherein. In at least one instance, a compression bushing can be used at aproximal or distal end of a firing drive screw within a cartridgechannel. Such a compression bushing can provide a compressive pre-loadto a firing drive screw, for example, once installed in a cartridgechannel. Such a compressive pre-load can prevent the firing drive screwfrom disengaging from any support elements supporting the firing drivescrew in the cartridge channel. For example, a compression bushing canbe used at one more ends of the firing drive screw to prevent theproximal end and/or distal end of the firing drive screw fromdisengaging from a corresponding support such as, for example, arcuateflanges extending from the cartridge channel.

A compressive pre-load can be induced by a spring, a longitudinal screw,and/or a rivet, for example, on a compression bushing. In such aninstance, the compression bushing will tend to expand radially under acompressive pre-load. Such radial expansion can fill an annular cradlesupport and/or float cavity such as those discussed herein. Thistendency for the compression bushing to fill such slots and/or cavities,for example, can help prevent the firing drive screw fromlongitudinally, laterally, and/or vertically de-seating from the supportelements such as the arcuate flanges discussed herein.

In at least one instance, a bushing and/or bearing configure to supporta rotary drive assembly disclosed herein comprises a flange extendingradially outward therefrom. The flange is configure to be positioned onthe side of the channel support flange opposite the distal support headof the firing drive screw. The radial flange can then be biased awayfrom the channel support flange and, thus, the distal support head by aspring. In such an instance, the spring would push against the channelsupport flange and the radial flange of the bushing, for example. Insuch an instance, the radial flange and the spring can be configured topull the distal support head into the channel support flange. In atleast one instance, this pulling force applied to the distal supporthead can be configured to seat the distal support head such that thefiring drive screw cannot be lifted directly out of the channel supportflange without first pulling the firing drive screw distally andovercoming the force applied by the spring. Overcoming the force wouldthen disengage the distal support head from the channel support flangeonly then allowing the firing drive screw to be lifted out of thechannel support flange.

Further to the above, the spring can be compressed by a distaltightening screw configured to pull the distal support head proximallytoward the channel support flange relative to the bushing comprising theradial flange, for example. Other embodiments are contemplated where abearing is positioned distal to the channel support flange and then anut is threaded onto the drive screw. The nut can then be turned tocompress the bearing against the channel support flange.

FIGS. 86 and 87 depict a surgical stapling assembly 5200 comprising asupport channel 5210 and a firing drive screw 5220 configured to actuatea firing member assembly such as the firing member assemblies disclosedherein. The firing drive screw 5220 defines a screw axis SA. Asdiscussed above, firing drive screws used within surgical end effectorassemblies can be subject to bending loads. As can be seen in FIG. 87,arrows 5230 indicate a bending load being applied to a distal end 5223of the firing drive screw 5220. The firing drive screw 5220 comprises aproximal ball joint 25221 mounted within a ball joint socket, or mount,5211 of a channel support 5211. Such a configuration permits the firingdrive screw 5220 to pivot relative to the channel support 5211 uponexperiencing a bending load. In at least one instance, the ball joint5221 and socket 5211 permit the firing drive screw 5220 to pivot withoutsignificantly bending the firing drive screw 5220. Bending can causebinding of the threaded portion 5225 and a firing member assembly, forexample. The ball and socket joint can be finely tuned to permit apredefined amount of pivot so as to not permit the firing drive screw5220 to pivot outside of the permitted predefined amount and possiblycause other issues within an end effector assembly. In at least oneinstance, the proximal mounting location of the firing drive screw 5220comprises a radial and/or spherical shape to permit a slight rotation ofthe firing drive screw 5220 relative to the screw axis SA. Such aconfiguration can also prevent binding and/or gouging of the firingdrive screw 5220 within the proximal mounting location.

In at least one instance, a proximal and/or distal end of a drive screwis support within a channel and/or anvil, for example, by way of morethan one support flange extending from the channel and/or anvil. Forexample, the more than one support flange can comprise a plurality offlanges in series with each other. One or more corresponding thrustbearings of the drive screw can be configured to be supported againstthe more than one support flange. Such a configuration can help supportthe drive screw should the drive screw want to move proximally anddistally, for example. In at least one instance, a separate thrustbearing is provided on the drive screw for each support flange extendingfrom the channel and/or anvil, for example. In at least one instance,each thrust bearing is configured to engage only its correspondingsupport flange. In other instances, one thrust bearing is providedbetween two flanges where the one thrust bearing is configured to engageboth flanges in a proximal direction and a distal direction. In such aninstance, one or more additional thrust bearings can be providedproximal to both support flanges and/or distal to both support flanges.Such arrangements may provide multiple thrust surfaces as opposed to asingle thrust surface for a drive screw.

In at least one instance, a thrust surface of a support flange, forexample, comprises a recessed inner donut hole, for example. In such aninstance, a thrust bearing of a drive screw can be configured to bereceived within the recessed inner donut hole. In at least one instance,a deformable thrust bearing is compressed into the recessed hole. In atleast one instance, the deformable thrust bearing comprises a diameterwhich is greater than an outer diameter of the recessed hole. Such aconfiguration can provide additional support to the drive screw. In atleast one instance, the deformable thrust bearing comprises a soft,low-density polyethylene washer. In at least one instance, the thrustbearing is compressed using an orbital forming process. In at least oneinstance, the thrust bearing can comprise a threaded washer, forexample.

In various instances, springs and/or magnets can be integrated invarious components of an end effector assembly to allow variouscomponents of the end effector assembly to float and/or move relative toeach other under load. For example, springs and/or magnets can beintegrated in proximal and/or distal mount locations where a firingdrive screw is supported by a cartridge channel, for example. Anotherexample includes integrating springs and/or magnets in a firing memberassembly to permit a drive nut thereof to float relative to a primarybody portion, for example.

FIGS. 88-91 depict a firing member assembly 5300 configured to push asled and/or cutting member through a staple firing stroke within an endeffector assembly. The firing member assembly 5300 comprises a primarybody portion 5010 and a threaded drive nut 5350 configured to bethreadably coupled to a firing drive screw. The drive nut 5350 isconfigured to apply axial drive forces to the primary body portion 5010to push and pull the primary body portion 5010 through an end effectorassembly. The primary body portion 5010 comprises an upper portion 5311configured to engage a first jaw of the end effector assembly and alower portion 5315 configured to engage a second jaw of the end effectorassembly. The lower portion 5315 comprises a proximal portion 5316 and adistal portion 5320 each configured to non-threadably receive the firingdrive screw therethrough. A drive nut cavity 5330 is defined between theproximal portion 5316 and the distal portion 5320 which is configured toreceive the drive nut 5350 therein. The firing member assembly 5300further comprises magnetic elements 5360 configured to couple the drivenut 5350 to the primary body portion 5310.

The magnetic elements 5360 can comprise cylindrical rods, or pins,and/or rectangular rods, or pins, for example. Nonetheless, one of themagnetic elements 5360 is attached to and spring loaded by a spring 5361within a proximal channel 5363 defined in the proximal portion 5316.Another one of the magnetic elements 5360 is attached to and springloaded by a spring 5361 within a distal channel 5365 defined in thedistal portion 5320. To mount the drive nut 5350 to the body portion5310, the magnetic elements 5360 are retracted in their respectivechannels 5363, 5365 by externally presented magnets 5370 (FIG. 90) whichare configured to overcome the spring force applied to the magneticelements by the springs 5361. Only then can the drive nut 5350 beinserted into the drive nut cavity 5330. Once the drive nut 5350 is inposition, the externally presented magnets 5370 may be moved away fromthe magnetic elements 5360 to allow the springs 5361 to bias themagnetic elements 5360 inwardly toward the drive nut 5350.

Specifically, the magnetic elements 5360 are configured to reside withina corresponding proximal channel 5351 defined in the drive nut 5350 anda corresponding distal channel 5355 defined in the drive nut 5350. Thechannels 5351, 5355 comprise a width and/or diameter which is greaterthan the width and/or diameter of the magnetic elements 5360. Thisdifference in size allows the drive nut 5350 to float relative to theprimary body portion 5310. The amount of floatation of the drive nut5350 relative to the primary body portion 5310 may be defined andlimited, at least in part, by the difference 5371 in size of themagnetic elements 5360 and the channels 5351, 5355. In at least oneinstance, one of the width and/or height is substantially the same asthe width and/or height of the magnetic elements 5360. Such aconfiguration will permit floatation of the drive nut in only one plane.For example, if the vertical height of the magnetic elements 5360 andthe drive nut channels 5351, 5355 are substantially the same and thewidth of the drive nut channels 5351, 5355 are greater than the width ofthe magnetic elements 5360, the drive nut 5350 is permitted to floatonly horizontally, or laterally, with respect to the primary bodyportion 5310. On the other hand, where the widths are substantially thesame and the vertical heights differ, the drive nut 5350 is permitted tofloat only vertically with respect to the primary body portion 5310. Anyfloatation may be ultimately limited by the size of drive screw ducts ofthe proximal portion 5316 and the distal portion 5320, as discussed ingreater detail above.

In at least one instance, the channels, or pockets, 5363, 5365 may bemachined into a metal primary body portion. In at least one instance,the channels, or pockets, 5351, 5355 may be part of an injection moldwhen manufacturing the drive nut 5350. In at least one instance, themagnetic elements 5360 can comprise steel pins, for example. In at leastone instance, the arrangement discussed above can reduce the need forexact alignment of an internal threaded channel defined in the drive nutto be coupled with the firing drive screw with corresponding drive screwducts of the primary body portion. In such an instance, if the internalthreaded channel is molded slightly off center with respect to thecorresponding drive screw ducts of the primary body portion, themagnetic element arrangement discussed above can permit the drive nut5350 to float into alignment with the primary body portion 5310. Theflotation of the drive nut 5350 may also help prevent binding of thedrive nut 5350 and a firing drive screw, for example. In at least oneinstance, a third degree of motion can be controlled and defined by theproximal portion 5316 and distal portion 5320 which can define theamount flotation, if any, which is permitted along a longitudinal axisrelative to the primary body portion 5310.

In various instances, a firing drive screw can be configured so as toprovide a compliant drive screw which can accommodate various loadsexperienced by the firing drive screw and reduce the likelihood of drivescrew binding, for example. Such a compliant drive screw canautomatically adapt and/or conform under different loaded conditions,for example. Such compliance may result in changing the shape of thedrive screw itself, as discussed in greater detail below.

FIGS. 92 and 93 depict a firing drive screw 5400 configured toautomatically adapt under load. The firing drive screw 5400 comprises acable or primary core member 5410 comprising a proximal end 5401 and adistal end 5403. The distal end 5403 may comprise a flange portionextending directly therefrom and/or a press fit thrust bearing, forexample. The firing drive screw 5400 also comprises a spring or helicalmember 5420 defining individual threaded sections 5421 configured toprovide a threaded interface for a threaded firing member assembly, forexample. The primary core member 5410 comprises a flexible material suchthat the primary core member 5410 can flex and adapt its shape underload. Along with the primary core member 5410, the helical member 5420also comprises a flexible material such that the helical member 5420 canflex along with the primary core member 5410 under load. Thisflexibility of the core member 5410 and the helical member 5420 allowsthe individual threaded sections 5421 to shift relative to each other.Each individual threaded section 5421 can shift relative to one another.However, the threaded sections 5421 can be configured to shiftsemi-independently. Such a configuration can permit slight shifting ofeach member 5421; however, all of the threaded sections 5421 are part ofthe single helical member 5420 so shifting of one threaded section 5421can cause some shifting of one or more adjacent helical members and soon. This can also be referred to as splaying of the threaded sections5421 when the firing drive screw 5420 is under load. The firing drivescrew 5420 can reduce the likelihood of drive screw binding under load.In various instances, the primary core member 5410 and the helicalmember can comprise different materials. Although the schematiccross-sectional view of FIG. 93 depicts a space or gap between theinside diameter of the helical member 5420 and the outside diameter ofthe primary core member 5410, in other instances the inside diameter ofthe helical member 5420 is in contact and/or abutting the outsidediameter of the primary core member 5410.

FIG. 94 is a schematic representation of a firing assembly 5500comprising a flexible firing drive screw 5550. The firing drive screw5550 may comprise many similarities to the firing drive screw 5400, forexample, among other disclosed herein. The firing assembly 5500comprises a firing drive screw 5550 mounted to a channel frame 5510. Aproximal drive member, or solid bushing, 5551 of the firing drive screw5550 comprises a flange 5552 configured to be supported by a proximalend 5511 of the channel frame 5510. A distal portion 5556 of the firingdrive screw 5550 is configured to be support by a distal support flange5513 extending from the channel frame 5512. The firing drive screw 5550further comprises a flexible core member 5556 and a helical member 5554surrounding the flexible core member 5556 and defining threadedsections, or regions, 5555. The helical member 5554 is attached to theproximal drive member 5551 and a sleeve/plug 5557 is fixedly attached tothe distal portion 5556 of the firing drive screw 5550. For example,proximal drive member 5551 can be swaged onto the flexible core member5556 of the firing drive screw 5556. The distal portion 5556 comprises athreaded section 5558, bushings 5559, and a distal nut 5560 threadablycoupled to the threaded section 5558. A pair of bushings 5559 arepositioned proximal to the distal nut 5560 in the socket and cansandwiched between the distal nut 560 and the distal support flange 551(see, e.g. bearings 5034 in FIG. 82).

In at least one instance, the inner diameter of the helical member 5554is configured to surround and contact an outer diameter of the flexiblecore member 5553. The helical member 5554 may comprise a type of coilspring, for example. The flexible core member 5553 may comprise aflexible cable, for example. In at least one instance, the helicalmember 5554 is manufactured with an inner diameter that is less than theouter diameter of the flexible core member 5553. In such an instance,the helical member 5554 can be counter-rotated to increase its innerdiameter for assembly onto the flexible core member 5553. Once thehelical member 5554 is positioned on the flexible core member 5553, thehelical member 5554 can be released. Once the helical member 5554 isreleased, it will bias back to its neutral, non-loaded configuration andsynch, or pinch, itself tightly to the flexible core member 5553. In atleast one instance, the helical member 5554 is welded to the flexiblecore member 5553 at various locations along the length of the flexiblecore member 5553.

In at least one instance, the nut 5560 is configured to be tightenedand/or loosened to provide the desired configuration of the helicalmember 5554. Tightening and/or loosening the nut 5560 can also allow foradjustment of tension of the flexible core member 5553. Adjusting thetension of the flexible core member 5553 can directly correlate to theamount of deflection permitted of the flexible core member 5553 alongits length under load. A tighter cable may permit less flexion than alooser cable, for example. This can be tuned during manufacturing to adesired tension, for example. Embodiments are envisioned where it istuned differently for different size cartridges and/or surgical staplingsystems requiring different firing forces, for example.

In various instances, a firing drive screw is provided that isconfigured to minimize plastic deformation thereof under various loads.Such a firing drive screw can comprise variations in cross-sectionalgeometry along its longitudinal length. Such variations can result in aportion of a firing drive screw which is more flexible than an adjacentportion of the firing drive screw. The more flexible portion of thefiring drive screw may be subject to greater bending loads than the lessflexible portion, for example. Variations of the firing drive screw canbe located at a proximal portion, an intermediate portion, a distalportion, or any combination thereof. Locations of variations can dependon application and areas of the firing drive screw subject to thehighest loads, for example.

FIG. 95 depicts a firing drive screw 5600 configured to be used with asurgical stapling assembly such the surgical stapling assembliesdiscussed herein. The firing drive screw 5600 comprises a proximaldriven end 5601 configured to be attached to a rotary drive shaft. Thefiring drive screw 5600 also comprises a proximal flange 5602 configuredto be supported within a frame component of an end effector assembly,for example. The firing drive screw 5600 comprises a screw shaft 5610comprising a primary threaded portion 5613 and a proximal necked downportion 5611. The proximal necked down portion 5611 comprises a smallercross-sectional diameter than the primary threaded portion 5613. Such avariation in the cross-sectional diameter can permit slight bending ofthe necked down portion 5611 to reduce the over bending effect on theprimary threaded portion 5613. Reducing the bending effect on theprimary threaded portion 5613, where a firing member assembly isconfigured to be threadably driven proximally and distally relativethereto, can reduce the likelihood of drive screw binding in the sectionof the firing drive screw 5600 engaged with the firing member assembly.In at least one instance, a firing member assembly is also configured tothreadably travel through the necked down portion 5611; however, in atleast one instance, high drive forces may not be required through thelength of the stroke that consists of the necked down portion 5611.

FIGS. 96 and 97 depict a firing drive screw 5700 comprising a proximaldriven end 5701 and a mounting flange 5702. The firing drive screw 5700further comprises a proximal section 5720 of threads 5721 which isovermolded and/or insert molded, for example, onto a proximal portion5711 of a primary shaft 5710 of the firing drive screw 5700. The firingdrive screw 5700 comprises a primary threaded portion 5712, whichcomprises a cross-sectional diameter which is greater than the diameterof the proximal portion 5711. As discussed above, the variation incross-sectional diameter can permit flexion of the primary shaft 5710and localize the flexion to the proximal portion 5711 specifically so asto reduce the likelihood of drive screw binding with a drive nut of afiring member assembly. The threads 5721 can consist of a polymermaterial while the primary shaft 5710 consists of a metallic material,for example. The threads 5721 can help maintain a consistent threadpattern along a travel stroke of a firing member assembly threadablycoupled to the firing drive screw 5700.

In at least one instance, various portions along the length of a firingdrive screw comprise overmolded plastic threaded sections, for example.In at least one instance, various overmolded portions can accommodatemanufacturing tolerance differences between a drive nut of a firingassembly and a firing drive screw thread profile and, in certaininstances, can provide a more lubricious threaded engagement surface,for example. In at least one instance, a central section, midway througha firing stroke, section of a firing drive screw comprises a variedcross-sectional profile.

FIGS. 98-100 depict various types of shaft couplings 5810, 5820, 5830that can be used with a firing drive screw such as those firing drivescrews disclosed herein. The shaft couplings 5810, 5820, 5830 can bepositioned at any location along the length of a firing drive screw toprovide a location intended to localize bending of the firing drivescrew. The shaft couplings 5810, 5820, 5830 are configured to convertrotary shaft motion from one shaft to another shaft. The shaft couplings5810 can introduce little to no backlash in the firing drive screw withwhich it is employed. The shaft couplings 5810, 5820, 5830 can permit adegree of angular misalignment of shafts owing to bending forces appliedto a firing drive screw within an end effector, parallel misalignment ofshafts, and/or axial movement of shafts, for example.

The shaft coupling 5810 may be a beam coupling, for example. Thecoupling 5810 comprises a proximal hub 5811 configured to be attached toa distal end of a portion of a firing drive screw, a distal hub 5813configured to be attached to a proximal end of another portion of afiring drive screw, and helical cutouts 5815 configured to flex duringscenarios of shaft misalignment.

The shaft coupling 5820 may be a bellow coupling, for example. Thecoupling 5820 comprises a proximal hub 5821 configured to be attached toa distal end of a portion of a firing drive screw, a distal hub 5823configured to be attached to a proximal end of another portion of afiring drive screw, and a flexible corrugation portion 5825 configuredto flex during scenarios of shaft misalignment.

The shaft coupling 5830 may be a curved jaw coupling, for example. Thecoupling 5830 comprises a proximal hub 5831 configured to be attached toa distal end of a portion of a firing drive screw, a distal hub 5833configured to be attached to a proximal end of another portion of afiring drive screw, and a spider gear comprising teeth 5835. The spidergear can comprise of a softer material configured to flex between thehubs 5831, 5833 while retaining drive engagement between the spidergear, the proximal hub 5831, and the distal hub 5833.

In an end effector assembly, such couplings 5810, 5820, and 5830 canpermit bending of a firing drive screw at the coupling itself and reducebending within the threaded shafts themselves. As discussed herein,bending of a threaded shaft can cause binding of a firing drive screwand a firing member assembly which are threadably coupled to each other.

FIGS. 101-103 depict a closure drive assembly 6000 comprising a closuredrive 6010 and a closure nut, or wedge, 6020 threadably coupled to theclosure drive 6010. The closure nut 6010 is configured to open and closea jaw 6040 of the closure drive assembly 6000 relative to an opposingjaw with cam nubs 6023 and cam surface 6021, respectively. The closuredrive assembly 6000 comprises a support element 6030 configured tosupport the closure drive 6010 thereon. The support element 6030 can befixed to a channel retainer, for example. The support element 6030comprises shaft seating flanges 6031, 6032 configured to support aclosure drive screw 6013 of the closure drive 6010 therein. The closuredrive 6010 further comprises a proximal driven portion 6010 configuredto be driven by a rotary closure drive shaft, a thrust bearing 6012configured to abut the flange 6031, and a distal thrust bearing portion6016 configured to abut the flange 6032.

The closure drive screw 6013 comprises a threaded section 6014 and adistal non-threaded section 6015. The closure nut 6020 further comprisesan internal threaded section 6025 configured to be threadably engagedwith the threaded section 6014 such that the closure nut can be advancedproximally and distally along the threaded section to open and close thejaw 6003. In at least one instance, the closure nut 6020 is configuredto be 3D printed onto the pre-manufactured closure drive 6010. Theclosure nut 6020 may comprise of a metal material and/or a polymermaterial, for example. The closure nut 6020 is configured to be printedaround the distal non-threaded section 6015. Such an arrangement canallow the internal threaded section 6025 of the closure nut 6020 to beprinted with an effective diameter which is slightly smaller than if theclosure nut were printed directly around the threaded section 6015.Printed on the closure drive screw 6013, the closure nut 6020 can beeffectively trapped between the bearing 6012 and bearing portion 6016preventing inadvertent disassembly after manufacturing. In at least oneinstance, the bearing 6012 and the bearing portion 6016 are printed onthe drive screw 6013 prior to printing of the closure nut 6020.

In at least one instance, one or more portions of the closure drive 6010are also 3D printed. In such an instance, the closure drive 6010 can be3D printed to be a size that is slightly larger than the desired size.For example, the closure drive 6010 can be scaled 0.5% larger than thedesired size. In such an instance, various details of the closure drive6010 requiring precise dimensions can be machined after the closuredrive 6010 is printed. Such a manufacturing process can decreasemachining waste and reduce the amount of time required to manufactureone or more parts, in certain instances. For example, a closure drivecomprising a shaft with a non-threaded section and a threaded sectionwhere the non-threaded section comprises a diameter less than or equalto a minor diameter of the threaded section requires at least theremoval of a ring of material with a width of the thread depth at thenon-threaded section. 3D printing such a closure drive can allow thenon-threaded section to be printed much closer to the minor diameter ofthe threads, albeit slightly larger for the reasons discussed above.

FIGS. 104 and 105 depict a closure drive 6100 comprising a drive screw6110 and a restraining collar 6120 configured to be secured to the drivescrew 6110. The restraining collar 6120 can be similar to the distalthrust bearing portion 6016 of the closure drive 6010. The restrainingcollar 6120 can be configured to support the closure drive 6110 againsta support flange, for example. The restraining collar 6120 may bereferred to as a washer, a nut, and/or a flange, for example. The drivescrew 6110 comprises a primary threaded portion 6111 comprising threads6112. The primary threaded portion 6111 can be configured to drive aclosure nut, for example, proximally and distally thereon to open andclose a jaw of an end effector.

The drive screw 6110 further comprises a distal end 6113 comprising anannular slot 6114 and a thread 6115. The annular slot 6114 is configuredto support the restraining collar 6120 therein. The thread 6115 isconfigured to permit the installation of the restraining collar 6120 aswell as prevent the removal of the restraining collar 6120 from thedrive screw 6110. The restraining collar 6120 comprises a proximal rampsurface 6122 defined therein. The proximal ramp surface 6122 isconfigured to permit the restraining collar 6120 to be screw onto thethread 6115 of the drive screw 6110 such that the restraining collar6120 can clear the thread 6115 and fit an internal support surface 6121to the annular slot 6114. Once installed onto the drive screw 6110, thethread 6115 resides distal to a distal, vertical, wall 6123 defined inthe restraining collar 6120. The distal wall 6123 is configured toprevent the restraining collar 6120 from being pulled off of the distalend 6113 of the drive screw 6110.

In at least one instance, the drive screw 6110 is machined and/or 3Dprinted from a metallic material. In at least one instance, therestraining collar 6120 is molded and/or 3D printed from a polymer. Inat least one instance, the restraining collar 6120 is constructed from amaterial which permits a degree of flexibility so as to allow therestraining collar 6120 to flex around and clear the thread 6115. Agreat degree of force may be required to install the restraining collar6120 onto the drive screw 6110. In at least one instance, a greaterdegree of force may be required to remove the restraining collar 6120from the drive screw 6110 at least owing the distal wall 6123.

In at least one instance, such a restraining collar can be used with afiring drive screw configured to threadably drive a firing memberassembly. In various instances, such a restraining collar is used at aproximal end of a drive screw, a distal end of a drive screw, or bothends of a drive screw.

In at least one instance, a restraining collar is installed onto a drivescrew with a lock washer. In such an instance, the thread and/or threadsthat the restraining collar is configured to be installed over can beconfigured so as to further tighten the locking engagement of the lockwasher and the restraining collar when the drive screw is under load,for example. For example, each end of the restraining collar cancomprise threads comprising opposite thread directions. For example, aproximal end of the restraining collar can comprise left handed threadsand a distal end of the restraining collar can comprise right handedthreads or vice-versa. Once installed, the restraining collar can beintroduced to the opposite thread pattern such that, as the restrainingcollar is encouraged off of the distal end of the drive screw, theopposite thread pattern can serve to further tighten the lockingengagement of the lock washer and restraining collar.

In at least one instance, a firing drive screw and/or closure drivescrew can be 3D printed. In such instances, various features can beprinted directly with the drive screw. For example, support flanges,bearings, restraining collars, etc., can be printed directly onto thedrive screw. In at least one instance, one or more of these variousfeatures can comprise a different material than the drive screw itself.In such instances, the features comprising a material different than thedrive screw can be printed directly onto the metal, for example, drivescrew. In at least one instance, the various features comprise the samematerial as the drive screw. In such instances, the various metal, forexample, features can be printed onto a metal drive screw using aprocess called directed energy deposition, for example. In at least oneinstance, various features can comprise a different material that, afterprinted, for example, onto the drive screw, can be welded to the drivescrew.

In various instances, the use of different material features on thedrive screw such as flanges, for example, can provide a lowercoefficient of friction between the flange and a support structure ascompared to a support structure and flange both comprising a metalmaterial, for example. Manufacturing the features after the primaryportion of the drive screw is machined, for example, can also reduce themanufacturing time and cost of the entire closure drive.

FIGS. 106 and 107 depict a drive assembly 6200 mounted to a channelflange 6210. The drive assembly 6200 comprises a drive screw shaft 6220comprising a threaded portion configured to be threadably coupled to afiring member of a surgical stapling assembly. The drive screw shaft6220 further comprises a distal end 6223 comprising a flanged end 6224and an annular slot 6225. To secure the drive screw shaft 6220 to thechannel flange 6210, a locking assembly 6230 is provided. The lockingassembly 6230 comprises a distal nut 6240 and a locking member 6250. Thelocking member 6250 is configured to be locked into the annular slot6225 to provide an abutment surface for the distal end 6223 of the drivescrew shaft 6220 to be secured against. The distal nut 6240 can bethreaded onto the distal end 6223 after the locking member 6250 ispositioned on the drive screw shaft 6220 against the channel flange6210. As the distal nut 6240 is tightened, or moved proximally towardthe channel flange 6210, the locking member 6250 can comprise a flexiblematerial so as to be urged into the annular slot 6225 by a rampedsurface 6241 of the distal nut 6240. In at least one instance, thelocking member 6250 is configured to mushroom and/or balloon in shape aspressure is applied thereto by the distal nut 6240. In at least oneinstance, the distal nut 6240 comprises a metal material. In at leastone instance, the locking member 6250 comprises a deformable restraintfor the drive screw shaft 6200. As a load is applied to the drive screwshaft in direction 6260, for example, the drive screw shaft 6220 isprevented from pulling proximally relative to the channel flange 6210because of the expansion of the locking member 6250. The flanged end6224 can transfer the load to the locking member 6250 which transfersthe load to the channel flange 6210.

In at least one instance, a drive screw shaft such as those discussedherein can be manufactured using a subtractive manufacturing processsuch as, for example, a Swiss screw manufacturing process, for example.Such a manufacturing process can reduce material waste and manufacturingtime of the drive screw, for example. Such a manufacturing process canalso allow for high precision machining of such a relatively small drivescrew where diameters along the length of such a drive screw shaft mayvary and comprise relatively small differences in size.

In various instances, a locking member, such as the locking member 6250,for example, comprises a rubber material and/or a low-densitypolyethylene and/or polypropylene, for example. The material of thelocking member can be selected based on its ability to shear under loadsuch that, under a pre-determined threshold load, the locking member mayshear to prevent other part failure within the system. Such a lockingmember can also automatically center a drive screw shaft as the lockingmember is installed by being uniformly restricted therearound.

In various instances, end effector assemblies such as those disclosedherein can comprise stackable supports configured to support one moredrives of the end effector assembly. For example, one or more stackablesupports are configured to support a closure drive and a firing drivewhich are non-concentric. The one or more stackable supports areconfigured to support one or more drives against a common frame elementsuch as, for example, a channel jaw.

FIGS. 108-110 depict a surgical stapling assembly 6300. The surgicalstapling assembly 6300 comprises a joint component 6310 and a channeljaw 6320. The channel jaw 6320 is attached the joint component 6310 by asecurement band, or ring, configured to be received within an annularslot 6315 of the joint component 6310. The channel jaw 6320 comprises abottom 6321 and vertical slots 6322 on each side of the channel jaw 6320configured to receive tabs 6314 on each side of the joint component6310. The joint component 6310 defines an articulation pin slot 6311therein. The channel jaw 6310 may be articulated about an axis definedby the articulation pin slot 6311. The joint component 6310 isconfigured to receive one or more drive shafts therethrough to drive aclosure drive 6340 and a firing drive 6350 of the surgical staplingassembly 6300.

The closure drive 6340 comprises a drive screw 6341 and a closure wedge6342 threadably coupled to the drive screw 6341. The closure wedge 6342is configured to be actuated proximally and distally with the drivescrew 6341 to open and close a jaw opposing the channel jaw 6320 suchas, for example, an anvil jaw. The firing drive 6350 comprises a drivescrew 6351 comprising a proximal end 6352 and a firing member assembly6353 configured to be threadably coupled to the drive screw 6351. Thefiring drive 6350 is configured to eject staples from a staple cartridgeand cut tissue of a patient during a staple firing stroke as the firingmember assembly 6350 is actuated along the drive screw 6351.

The closure drive 6340 and the firing drive 6350 are supported withinthe channel jaw 6320 by a lower support element, or mount, 6380 and anupper support element, or mount, 6370. The support elements 6370, 6380may be stackable and support one or more elements of the closure drive6340 and firing drive 6350. The lower support element 6380 comprises alower portion 6381 and an upper portion 6383. The lower portion 6381comprises a key 6382 configured to be received within a correspondingslot defined in the channel jaw 6320. Such a key and slot configurationcan prevent the lower support element 6380 from moving relative to thechannel jaw 6320. The upper portion 6383 comprises a shaft support 6384comprising a lower arcuate support portion 6385 and an upper arcuatesupport portion 6386. The lower arcuate support portion 6385 isconfigured to receive an input shaft 6355 of the firing drive 6350 whichis configured to couple and drive the proximal end 6352 of the drivescrew 6351. The upper arcuate support portion 6386 is configured toreceive and support the drive screw 6341 of the closure drive 6340.

The upper support element 6370 can be received on top of the lowersupport element 6380 in a track-like manner. For example, acorresponding cavity defined in the upper support element 6370 can beconfigured to receive the upper portion 6383 of the lower supportelement 6370 such that the upper support element 6370 fits and surroundsthe upper portion 6383 upon installation. The upper support element 6370further comprises a key 6371 configured to be received within acorresponding slot defined in the channel jaw 6320. The upper supportelement 6370 further comprises a top surface 6373 and a distal supporttab 6372 configured to receive and support a portion of the drive screw6341 therein. The top surface 6373 is configured to support a bottomsurface 6343 of the closure wedge 6342 thereon. In at least oneinstance, a closure wedge track is defined on the top surface 6373, andthe closure wedge 6342 can mate with and ride along the closure wedgetrack during proximal and distal travel. The upper support element 6370further comprises a window 6374 configured to receive the upper portion6383. Both the upper support element 6370 and the lower support element6380 can be supported by the bottom 6321 of the channel jaw 6320.

In at least one instance, the upper and/or lower support elements 6370,6380 can be supported within corresponding tracks defined in the channeljaw 6320 such that the upper and lower support elements 6370, 6380 arepermitted a degree of longitudinal travel while still being supported bythe channel jaw 6320. This can help during clamping, unclamping, and/orarticulation of an end effector assembly where various drive shaftcomponents are required to lengthen or shorten owing to the clamping,unclamping, and/or articulation motions and associated forces of the endeffector assembly.

In at least one instance, the upper and/or lower support elements 6370,6380 are manufactured from a single material into a single component.Such a configuration can be achieved using a metal machining process,for example. In at least one instance, the upper and/or lower supportelements 6370, 6380 are manufactured separately. In such an instance,one of the upper and lower support elements 6370, 6380 comprises amachined component and the other of the upper and lower support elements6370, 6380 comprises a sheet stamped component, for example. In at leastone instance, both of the upper and lower support elements 6370, 6380are stamped.

Various types of closure wedges and/or nuts are disclosed herein. Theclosure wedges can comprise a camming surface configured to close a jawand one or more camming surfaces configured to open the jaw. In variousinstance, angles of the corresponding cam surfaces can comprise steeperangles relative to the engaging surface of the jaw which they camminglyengage. The camming surfaces can be tuned such that the drive forcerequired from a corresponding closure drive screw is minimal whilemaintaining more than sufficient closure drive cam forces.

FIGS. 111-113 depict a closure drive assembly 6400 configured to openand close a jaw of an end effector assembly. The closure drive assembly6400 comprises a jaw support element 6410 and a closure drive 6420supported by support flanges 6411, 6413 of the jaw support element 6410.The closure drive 6420 comprises a drive screw shaft 6430 comprising aproximal end 6431 configured to be rotated by a rotary drive shaft, aproximal bearing portion 6432 configured to prevent the drive screwshaft 6430 from moving distally relative to the flange 6413, and athreaded portion 6433 configured to be threadably coupled to a closurewedge 6450. The drive screw shaft 6430 further comprises a distal end6434 supported within flange support slot 6412 of the flange 6411 andsecured to the flange 6411 by way of a clip 6440. The clip 6440 isconfigured to be received within a clip slot 6435 defined in the distalend 6435 of the drive screw shaft 6430. The clip 6440 is configured toprevent the drive screw shaft 6430 from moving proximally relative tothe flange 6411. The clip 6440 may comprise an e-clip, for example.However, any suitable clip, retention clip, and/or retention ring, maybe used. In at least one instance, the closure wedge 6450 may bethreaded onto the drive screw shaft 6430 from the distal end 6434.

FIGS. 114-117 depict a closure drive 6500 comprising a drive screw shaft6510 and a closure drive nut, or wedge, 6540 configured to open andclose a jaw of an end effector assembly. The drive screw shaft 6510comprises a proximal end 6511 and a distal end 6515. The proximal end6511 comprises a driven portion 6512 configured to be rotated by arotary drive shaft, a proximal bearing portion 6513, and a threadedportion 6514 configured to be threadably coupled to the closure wedge6540. The distal end 6515 comprises an attachment section 6516comprising a diameter less than the diameter of the drive screw shaft6510 immediately proximal to the attachment section 6516. The attachmentsection 6516 is configured to receive a locking member, or radial washer6520, thereon.

Turning now to FIGS. 116 and 117, installation of the locking member6520 will now be described. The distal end 6515 may be swaged, forexample, to radially expand the attachment section 6516. This radialexpansion can provide a frictional holding engagement between thelocking member 6520 and the attachment section 6516. A central slot 6517is provided. The slot 6517 can be used to insert a swaging tool thereinto expand the attachment section 6516 to lock the locking member 6520 inplace. In at least one instance, the locking member 6520 is deformableand swaging of the attachment section 6516, for example, is configuredto deform the locking member 6520 into an installed configuration.

In at least one instance, the locking member 6520 is pinned to theattachment section 6516 in addition to or in lieu of the swaging processdiscussed above. In at least one instance, the locking member 6520further comprises an annular groove and the attachment section 6516further comprises a corresponding annular slot defined on the outsidethereof configured to receive the annular groove of the locking member6520. In at least one instance, a hole is machined in the drive screwand a dowel pin is configured to be inserted into the hole to retain aclosure wedge on the drive screw.

In at least one instance, a high density polyethylene washer ispositioned proximal to the locking member 6520. The high densitypolyethylene washer may also comprise a deformable support flange suchthat the washer is deformed when the locking member 6520 is assembled tothe drive screw shaft 6510, for example.

In at least one instance, a deformable washer used herein comprises agrooved and/or knurled face. Such a grooved and/or knurled face can beused to compensate for tolerance stack-ups of various components withina drive system. For example, such a grooved and/or knurled face can wearslightly after a first stage of actuation after assembly so as tocompensate for tolerance stack-ups.

FIGS. 118-123 depict a firing drive assembly 7000 comprising a rotarydrive shaft 7010, a firing member 7020 threadably coupled to the rotarydrive shaft 7010, and a bailout assembly 7030 configured to threadablycouple the firing member 7020 to the rotary drive shaft 7010 and permitthe bailing out of and/or disengagement of the threaded engagementbetween the rotary drive shaft 7010 and firing member 7020. The rotarydrive shaft 7010 comprises a distal end 7011 and a threaded, or grooved,section 7013. The firing member 7020 comprises an upper flange, aproximal edge 7022, and a distal edge 7023. The firing member 7020further comprises a lower portion 7024 comprising a drive shaft duct7026 configured to receive the rotary drive shaft 7010 therethrough. Thelower portion 7024 further comprises a lower flange 7025.

The bailout assembly 7030 comprises bailout actuators, or cables, 7031and a housing 7032 defining a housing cavity 7033. The bailout assembly7030 further comprises a biasing plate 7040 and an actuator plate 7050.The actuator plate 7050 comprises a primary plate portion 7051 and apoint, or pin, 7052 extending inwardly therefrom to be received anddriven by the threaded section 7013 of the rotary drive shaft 7013. Thepin 7052 is configured to be received within a pin slot 7028 defined inthe lower portion 7024 to drivingly engage the threaded, or grooved,section 7013. The actuator plate 7050 is spring loaded against the lowerportion 7024 with springs 7060 positioned within spring slots 7027defined in the lower portion 7024. The springs 7060 are configured tobias the actuator plate 7050 out of threaded engagement with the rotarydrive shaft 7010.

To hold the actuator plate 7050 in threaded engagement with the rotarydrive shaft 7010, the biasing plate 7040 is positioned, or wedged,between the housing 7032 and the primary plate portion 7051 within thehousing cavity 7033. This wedging engagement overcomes the spring forceapplied to the actuator plate 7050 by the springs 7060 and keeps the pin7052 engaged with the threaded section 7013 of the rotary drive shaft7010. In various instances, the firing drive assembly 7000 may becomestuck or jammed within an end effector assembly due to a variety ofcircumstances. The bailout assembly 7030 allows for the firing member7020 to be disengaged from the rotary drive shaft 7010 and pulledproximally independently of the rotary drive shaft 7010 to overcome astuck or jammed scenario.

To bailout the firing drive assembly 7000, the pin 7052 is moved from aninward-most position (FIG. 120, FIG. 121) to an outward-most position(FIG. 122, FIG. 123) disengaging the pin 7052 and, thus, the firingmember 7020, from the rotary drive shaft 7010. To achieve this motion,the biasing plate 7040 is pulled proximally by the actuators 7031 tomove the biasing plate 7040 out of the way of the actuator plate 7050 soas to allow the springs 7060 to push the primary plate portion 7051 and,thus, the pin 7052 out of threaded engagement with the threaded section7013 of the rotary drive shaft 7010. At such point, the actuators 7031can continue to be pulled proximally to apply a pulling force to thefiring member 7020 through the biasing plate 7040. The housing cavity7033 comprises a proximal limit wall configured to transfer the pullingforce from the biasing plate 7040 to the firing member 7050. Once thefiring member 7020 is pulled into its proximal most position the endeffector assembly may be opened and removed from a surgical site, forexample.

In at least one instance, the firing drive assembly 7000 and endeffector assembly employing the firing drive assembly 7000 may not beusable again due to the nature of the bailout assembly 7030. Forexample, the bailout assembly 7030 may not be able to be reset back intothreaded engagement with the rotary drive shaft 7010. In at least oneinstance, the bailout assembly 7030 may be capable of being reset andreused. In at least one instance, another pin 7052 and correspondingstructure is provided on the other side of the firing member 7020. Thesame, or separate, cables may be provided to actuate the other pin insuch an instance.

In at least one instance, the actuators, or cables, may be controlledusing a geared pulley system. In at least one instance, the cables maybe motor driven. In at least one instance, the cables are manuallyactuatable. In at least one instance, the cables may be manuallyactuatable and motor driven. For example, during a power failure, themanual actuation method could be used where the motor driven system istemporarily down. In at least one instance, the cables are permitted tolengthen as the firing member is actuated so as to not prematurelyactuate the bailout assembly. The cables may be passively moved oractively moved to accommodate movement of the firing member.

In various instances, surgical stapling arrangements are provided whichare configured to form staples, such as traditional wire staples,differently within a single staple cartridge. More specifically, astaple cartridge may store staples with identical unformed heights,size, and shape, for example. In such an instance, different featuresare provided so as to form the same unformed staples into differentfinal formed configurations. In at least one instance, the variedforming of staples varies progressively along the lateral width of thestaple cartridge. More specifically, an inner row of staples may beformed into a planar, or 2D, formed configuration while an intermediaterow of staples and/or an outer row of staples may be formed into anon-planar, or 3D, formed configuration. Such an arrangement can providevaried stapled tissue compression along the lateral width of the staplecartridge.

Further to the above, such surgical stapling arrangements can comprisetissue gripping features, or staple cavity extensions, defined on a deckof the staple cartridge. Such tissue gripping features can vary in shapeand/or size, for example, laterally across the staple cartridge. Thedeck of the staple cartridge may comprise a curved surface where an apexof such a curved deck is defined at a longitudinal slot of the staplecartridge. The deck of the staple cartridge may also comprise one ormore flat surfaces either providing a single flat surface in which allof the staple rows are defined or a stepped deck arrangement wherevarious stepped portions of the deck comprise one or more correspondingstaple rows defined therein.

The tissue gripping features may also be interconnected along thelateral width of the staple cartridge. For example, on each side of alongitudinal slot of the staple cartridge, the staple cartridge maycomprise three rows of staple cavities and, thus, three rows of staplesremovably stored therein. The tissue gripping features, or deckprotrusions, may be positioned around each cavity of each row; however,the tissue gripping features can be interconnected between one or moreof the staple cavity rows while still varying in shape and/or size, forexample. Such tissue gripping features can provide varied tissuecompression along the lateral width of a staple cartridge. The varyingsize tissue gripping features can be advantageous when forming certainrows of staples into a non-planar, 3D configuration, and certain rows ofstaples into a planar, 2D configuration. Such features can be tunedspecifically for the corresponding staple configuration of the staplesto be formed through tissue gripped by the features. For example,gripping features configured to grip tissue to be stapled between ananvil and a row of staple cavities comprising staples configured to beformed into a non-planar configuration can comprise a first profile andgripping features configured to grip tissue to be stapled between ananvil and a row of staple cavities comprising staples configured to beformed into a planar configuration can comprise a second profile,wherein the first profile is different than second profile. In certaininstances, the gripping features aligned with the rows of 3D staples caninclude cutouts in the areas where curved, formed legs would interfere.For example, the rows aligned with 2D staples can include full grippingfeatures surrounding the staple cavity, and the rows aligned with the 3Dstaples can include gripping features with cutouts therearound toaccommodate the staple legs during the 3D formation thereof.

In various instances, staples formed into a planar configuration andstaples formed into a non-planar configuration may result in differentformed compression heights. This can be attributed to a distancerequired to be traveled by legs of each staple to their correspondingstaple forming pocket defined in an anvil. For example, legs of staplesformed into a non-planar configuration may have to travel on a diagonalto a corresponding staple forming pocket. Without altering any otherfeatures of the stapling assembly, this distance may be farther than thedistance required to be traveled by legs of staples formed into a planarconfiguration to a corresponding staple forming pocket.

In various instances, the distance which each leg must travel to beformed into its corresponding configuration, non-planar or planar, maybe tuned by altering one or more features of a surgical staplingassembly. In at least one instance, the depths of staple forming pocketsdefined in the anvil are adjusted corresponding to the formedconfiguration of the staple to be formed thereby. In at least oneinstance, the unformed length of the staples are configured to beadjusted corresponding to the formed configuration of the staple to beformed thereby. In at least one instance, a corresponding driver heightis adjusted corresponding to the formed configuration of the staple tobe formed thereby. In at least one instance, one or more of theseadjustments are combined together to accommodate 2D formed staples and3D formed staples.

FIGS. 124-128 depict a surgical stapling assembly 8000. The surgicalstapling assembly 8000 comprises a cartridge jaw 8001 comprising acartridge channel 8010 and a staple cartridge 8020. The surgicalstapling assembly 8000 also comprises an anvil jaw 8003 comprising ananvil 8050. The staple cartridge 8020 comprises a plurality of staplecavities 8030 and a longitudinal slot 8022 defined in a cartridge deck8021. The staple cartridge 8020 also comprises and a plurality oftissue-gripping features, or cavity extensions, 8040 defined on the deck8021. The staple cavities 8030 are aligned in longitudinal rows offsetwith respect to each other. In this instance, the staple cartridge 8020comprises three rows of staple cavities on each side of the longitudinalslot; however, any suitable number of rows of staple cavities can beemployed. The staple cavities 8030 are configured to removably storestaples which are configured to be ejected toward staple forming pocketsdefined in an anvil surface 8051 of the anvil 8050.

Referring to FIGS. 125 and 126, the anvil 8050 comprises an anvil slot8052 defined in the anvil surface 8051. The anvil 8050 further comprisesa pair of inner staple forming pocket rows 8061, a pair of intermediatestaple forming pocket rows 8063, and a pair of outer staple formingpocket rows 8065. The rows 8061, 8063, 8065 are aligned withcorresponding rows of the staple cavities 8030. The inner staple row8081 comprises staples 8070 which are configured to be formed by thestaple forming pocket rows 8061, the intermediate staple row 8082comprises staples 8070 which are configured to be formed by the stapleforming pocket rows 8063, and the outer staple row 8083 comprisesstaples 8075 which are configured to be formed by the staple formingpocket rows 8065. The staple tip entry location of the pockets in thestapling forming pocket row 8065 is aligned, or substantially aligned,with the tips of the staples in the outer staple row 8065; however, thestaple tip exit location of those pockets can be laterally offset fromthe staples positioned in the outer staple row 8065. The staples 8070,8075 comprise traditional wire staples. The staples 8070, 8075 comprisethe same unformed height. The staples 8070 are formed into a planarconfiguration while the staples 8075 are formed into a non-planarconfiguration.

Each pair of forming pockets of the row 8061 comprises a proximalforming pocket 8061A and a distal forming pocket 8061B. Each pair offorming pockets of the row 8063 comprises a proximal forming pocket8063A and a distal forming pocket 8063B. Each pair of forming pockets ofthe row 8065 comprises a proximal forming pocket 8065A and a distalforming pocket 8065B. The forming pockets 8061A, 8061B comprisecenterline axes, or longitudinal pocket axes, which are aligned witheach other along the row 8061. Similarly, the forming pockets 8063A,8063B comprise centerline axes, or longitudinal pocket axes, which arealigned with each other along the row 8063. The forming pockets 8065A,8065B comprise centerline axes, or transverse pocket axes, which aretransverse with respect to the centerline axes of the pockets 8061A,8061B and the centerline axes of the pockets 8063A, 8063B. Thecenterline axes of the pockets 8065A, 8065B may be substantiallyparallel to each other. Further to the above, a proximal leg of one ofthe staples 8070 is configured to enter the proximal forming pocket8065A and a distal leg of the staple is configured to enter the distalforming pocket 8065B. The forming pockets 8065A, 8065B are configured todirect the legs of the staple 8075 laterally away from a crown of thestaple or, laterally away from each other (see FIG. 126). This variancein 2D formed staples and 3D formed staples laterally along the width ofthe stapling assembly 8000 with respect to a longitudinal axis definedthereby can provide varied tissue compression on the stapled tissue. Forexample, the outer 3D staples may provide less tissue compression ascompared to the inner 2D formed staples near the cut line of the tissue.

As can be seen in FIG. 125, a gap is defined longitudinally between eachpair of forming pockets 8061A, 8061B, a gap is defined longitudinallybetween each pair of forming pockets 8063A, 8063B, and a gap is definedbetween each pair of forming pockets 8065A, 8065B. The gap definedbetween the forming pockets 8061A, 8061B may be substantially the sameand/or similar to the gap defined between the forming pockets 8063A,8063B. The gap defined between the forming pockets 8065A, 8065B islarger than the gap defined between the forming pockets 8061A, 8061B andthe gap defined between the forming pockets 8063A, 8063B. The gapdefined between the forming pockets 8065A, 8065B may be defined as thespace intermediate the forming pockets 8065A, 8065B.

As can be seen in FIGS. 127 and 128, the staples 8070 are formed into aplanar configuration and the staples 8075 are formed into a non-planarconfiguration. The staple 8070 comprises a crown 8071 and legs 8072extending from the crown 8071. The legs 8072 further comprise staple tipportions 8073 configured to pierce tissue and enter correspondingforming pockets. The staples 8070 define a formed compression height“X1” which is the effective height of tissue compression captured by thestaple 8070. The staple 8075 comprises a crown 8076 and legs 8077extending from the crown 8076. The legs 8077 further comprise staple tipportions 8078 configured to pierce tissue and enter correspondingforming pockets. The staples 8075 define a formed compression height“X2” which is the effective height of tissue compression captured by thestaple 8075. Because of the non-planar formed configuration of thestaple 8075, the formed compression height X2 is taller than the formedcompression height X1. In at least one instance, this is desirable andcan provide a progressive reduction in compression as the staple linesmove laterally away from the cut line. For example, a tighter formedcompression height near the cut line may provide adequate tissue sealingpressure and a looser formed compression height away from the cut lineprogressively reduces pressure on the tissue as the staple lines movelaterally outwardly with respect to the cut line.

In at least one instance, the legs 8077 are formed at different anglesaway from the crown 8076 with respect to each other. For example, aproximal leg can be formed away from the crown at a first angle and thedistal leg can be formed away from the crown in the opposite directionat a second angle. The first angle is different than the second angle.This would allow for a narrow footprint of the corresponding stapleforming pockets. Moreover, when stamping these pocket shapes into theanvil, the different angles and/or narrower footprint can ensure thatthe wall between adjacent rows of forming pockets is sufficientlymaintained, which can prevent bleeding or washout of features in one rowinto those in an adjacent row during the stamping process.

3D staples can be intermixed within and/or across longitudinal rows,which can maximum use of the anvil surface and further nest the pocketsand allow a narrower footprint. In certain instances, intermixing of 3Dstaple pockets can improve tissue pressure dispersion along the anvil.In at least one instance, the 3D staple pockets can be positioned alongan outermost row of pockets to further ease and/or taper the tissuepressure along the edges of the staple line farthest from the cut line.

In various instances, the gripping features 8040 and the curved deck8021 can provide laterally varying tissue gaps. More specifically, thegap for tissue to be captured between each corresponding row of staplecavities and staple forming pockets is varied between each row. Theouter-most row comprises the tallest gripping features as compared tothe inner row and intermediate row. This may provide additional tissuecompression in a row where the 3D staples are configured to be formed.This may provide greater stability during staple forming owing to theadditional cavity extension length of the outer staple cavities. Thetaller gripping features can maintain a similar compression profilebetween the gripping features and the corresponding forming pockets;however, the portion of the deck surface 8021 that the outer row ofstaple cavities are defined in is further away from the anvil than theportion of the deck surface 8021 that the inner row of staple cavitiesand the intermediate row of staple cavities are defined in due to thelateral curvature of the deck. Collectively, the taller grippingfeatures and the lower deck surface can provide a more stable platformfor 3D formed staples in certain instances.

In various instances, flat form, or stamped, staples can be used inaddition to or in lieu of wire staples. In various instances, two of thethree rows of staples on each side of a cartridge are configured to beformed into a non-planar configuration while the other one of the threerows on that side of the cartridge is configured to be formed into aplanar configuration. In at least one instance, the same longitudinalrow of staples comprises both planar formed staples as well asnon-planar formed staples. In at least one instance, the unformed heightof staples within the same row is varied. In at least one instance, theunformed height of staples within different rows is varied. In at leastone instance, planar staples and non-planar staples are varied alongaxes transverse to a longitudinal slot of a staple cartridge to spreadstaple pressure. In at least one instance, staple legs of non-planarformed staples are formed laterally on one side of the crown rather thanopposite directions relative to the crown away from each other. In suchan instance, the row gap between each row can be substantially similarat least because the legs, although forming away from the crown uponejection, can be formed back toward the crown to tighten the staplelines. Such a configuration can help maintain a consistent lateral rowgap between each row of staple forming pockets.

As discussed above, one or more adjustments can be made to vary thefinal formed height and/or compression height of the staples as thereform can vary laterally, row-to-row, for example. FIG. 129 depicts ananvil 8100 configured to deform staples ejected from a staple cartridge.The anvil 8100 comprises an anvil body 8110 comprising an anvil surface8111 and a firing member slot 8112 defined in the anvil body 8110. Theanvil surface 8111 comprises a plurality of staple forming pocket rowscomprising inner rows 8121, intermediate rows 8123, and outer rows 8125.The inner and intermediate rows 8121, 8123 are configured to formstaples into a planar configuration and the outer rows 8125 areconfigured to form staples into a non-planar configuration. As can beseen in FIG. 129, the inner and intermediate rows 8121, 8123 define apocket depth 8131 and the outer rows define a pocket depth 8135 which isshallower than the pocket depth 8131. This shallower pocket depth canaccommodate for loss in compression or final formed height owing to thediagonal forming path of the non-planar staples. In at least oneinstance, the pocket depths are tuned so that the final compressionheight is the same between non-planar staples and planar staples. Inanother instance, the pocket depths are tuned so that the finalcompression heights between non-planar staples and planar staples aredifferent.

FIG. 130 depicts a sled 8200 comprising inner ramps 8220 and outer ramps8230. The inner ramps are configured to lift staples a height 8221 andthe outer ramps 8230 are configured to lift staples a height 8231. Theramps 8220 are configured to lift staples to be formed into a planarconfiguration and the ramps 8230 are configured to lift staples to beformed into a non-planar configuration. The height 8231 may accommodatefor loss in compression or final formed height owing to the diagonalforming path of the non-planar staples.

FIG. 131 depicts staples 8300 to be used with a surgical staplingassembly. The staples 8300 comprise a first staple 8310 comprising afirst unformed height 8311 and a second staple 8320 comprising a secondunformed height 8321. The first unformed height 8311 is less than thesecond unformed height 8321. The different unformed heights canaccommodate for loss in compression or final formed height owing to thediagonal forming path of the non-planar staples. The second staple 8320can be configured to be formed into a non-planar configuration while thefirst staple 8310 can be configured to be formed into a planarconfiguration.

FIGS. 132 and 133 depict staples 8410, 8420. The staple 8410 formed intoa planar configuration defines a final compression height 8411 and thestaple 8420 formed into a non-planar configuration defines finalcompression height 8421. The final compression height 8421 is less thanthe compression height 8411; however, the staple 8420 defines a distance8422 defined between the apex of each formed leg and the crown. Thedistance 8422 may be substantially equal to the final compression height8411. The distance 8422 may be the effective compression height of thestaple 8420.

In various instances, surgical stapling assemblies are provided whichare configured to overdrive staples from a staple cartridge. The amountof staple overdrive may vary from row to row. In various instances,staple drivers can comprising varying amounts of support from acorresponding staple cartridge support wall. More specifically, innerstaple drivers can be supported less by a staple cartridge support wallthan outer staple drivers owing to the geometry of the cartridge bodyand firing assembly and/or drive screw therein. In various instances, atissue gap can be varied from row to row while maintaining a similar, orthe same, driving distance between the rows.

FIGS. 134-136 depict a surgical stapling assembly 8500. The surgicalstapling assembly 8500 comprises a lower jaw 8501 and an upper jaw 8502.The lower jaw 8501 comprises a cartridge channel 8510 and a staplecartridge 8520 configured to be received within the cartridge channel8510. The upper jaw 8502 comprises an anvil 8530 comprising an anvilbody 8531. The anvil body 8531 comprises an anvil surface 8532 and aplurality of forming pockets defined in the anvil surface 8532. Theanvil surface 8532 comprises inner forming pockets 8533, intermediateforming pockets 8534, and outer forming pockets 8535. The staplecartridge comprises a plurality of staple cavities 8522 comprising innerstaple cavities 8522A aligned with inner forming pockets 8533,intermediate staple cavities 85228 aligned with intermediate formingpockets 8534, and outer cavities 8522C aligned with outer formingpockets 8534. The staple cavities 8522 are configured to store acorresponding driver and staple therein to be ejected to the formingpockets aligned therewith.

The staple cartridge 8520 comprises a curved cartridge deck 8529comprising a plurality of staple cavities 8522 defined therein and aplurality of tissue gripping features, or cavity extensions, 8523, 8524,8525 extending from the cartridge deck 8529. The staple cartridge 8520also comprises a sled 8550 comprising ramps 8551, 8552. The staplecartridge 8520 comprises a plurality of drivers 8540 sequentiallyaligned to eject rows of staples from the staple cavities when lifted byramps 8551, 8552. Each driver 8540 comprises an inner row support, orinner support column, 8541 configured to support and drive a staple tobe stored and ejected from an inner staple cavity 8522A, an intermediaterow support, or intermediate support column, 8542 configured to supportand drive a staple to be stored and ejected from an intermediate staplecavity 85228, and an outer row support, or outer support column, 8543configured to support and drive a staple to be stored and ejected froman outer staple cavity 8522C.

As can be seen in FIG. 135, the staple cartridge 8520 comprises innersupport walls 8526A configured to support inner row support 8541 as thedriver 8540 is lifted by sled 8550, intermediate support walls, orcolumns, 8526B configured to support intermediate row support 8542 asthe driver 8540 is lifted by sled 8550, and outer support walls 8526 cconfigured to support outer row support 8543 as the driver 8540 islifted by sled 8550. As can be seen in FIG. 135, the level of supportcontact between each support 8541, 8542, 8543 and its correspondingsupport wall 8526A, 8526B, 8526C varies from row to row. In an unfiredposition, the outer support 8541 has the most support contact, theintermediate support 8542 has less support contact than the outersupport 8541, and the inner support 8541 has the least amount of supportcontact. As can also be seen in FIG. 135, the supports 8541, 8542, 8543are overdriven to the same limit resulting in the same driving formingdistance of each staple supported by the supports 8541, 8542, 8543;however, the amount of overdrive relative to their correspondinggripping feature 8523, 8524, 8525 varies from row to row. The outer rowis overdriven past its gripping features the most, and the inner row isoverdrive past its gripping features the least.

As discussed herein, staple cartridges can be replaced within a surgicalstapling assembly. In various instances, anvil plates are provided whichcan also be replaced. In such instances, the anvil plate may come with acorresponding staple cartridge such that a fresh staple cartridge andanvil plate are packaged together and are replaced within the surgicalstapling assembly together. In such instances, various features of theanvil plates and corresponding staple cartridge can be tunedspecifically for each other. For example, different anvil plates cancomprise staple forming pockets with different patterns, staple formingpockets with different forming depths, and/or varied staple formingpocket types from row to row, for example, among other things.

A universal fitment profile can be used for a variety of anvil platessuch that the stapling assembly may receive several different anvilplates. Replacing an anvil plate can also provide fresh staple formingpockets. The anvil plate and staple cartridge can be paired based onstaple leg length, types of staples stored in the staple cartridge,and/or desired formed height of the staples. In such instances, an anviljaw configured to receive the anvil plate can be manufactured with orwithout staple forming pockets defined directly thereon. This may reducemanufacturing costs because the anvil jaw can be reused in differentscenarios rather than introducing an entirely different surgicalstapling instrument with different types of forming pockets.

FIGS. 137-139 depict a surgical stapling assembly 8600 comprising afirst jaw 8601 and a second jaw 8603 movable relative to the first jaw8601 to clamp tissue therebetween. The surgical stapling assembly 8600is configured to cut and staple tissue captured between the jaws 8601,8603. The first jaw 8601 comprises a replaceable staple cartridge 8620configured to removably store a plurality of staples in a plurality ofstaple cavities 8622 therein defined in a deck surface 8621 of thestaple cartridge 8620. The first jaw 8601 further comprises a cartridgechannel 8610 configured to receive the replaceable staple cartridge 8620therein. As discussed above, various different types of staplecartridges can be installed within the cartridge channel 8610. Variousdifferences between replaceable staple cartridges can include differentunformed staple leg height and/or orientation, different cartridgelength, and/or different staple diameter, for example.

The second jaw 8603 comprises a replaceable anvil plate 8640 comprisingan anvil surface 8641 and a plurality of forming pockets 8642 defined inthe anvil surface 8641. The second jaw 8603 further comprises an upperanvil jaw portion 8630 configured to receive the replaceable anvil plate8640 therein. In at least one instance, the replaceable anvil plate 8640is slid into a distal end of the anvil jaw portion 8630. In at least oneinstance, the replaceable anvil plate 8640 is configured to be snappedinto the anvil jaw portion 8630. In at least one instance, the anvil jawportion 8630 comprises deformable arms made of a metallic material, forexample, hanging from the perimeter of the anvil jaw portion 8630. Thedeformable arms can be configured to deform upon clamping of the jaws8601, 8603 together after positioning the anvil plate 8640. Uponattaining a fully clamped position, the deformable arms are deformedand, in their deformed configuration, are configured to grasp and retainthe anvil plate 8640 to the anvil jaw portion 8630. In at least oneinstance, a clampable member is configured to be clamped by the jaws8601, 8603 to affix the anvil plate 8640 to the anvil jaw portion 8630.In such an instance, the clampable member can be responsible fordeforming the deformable arms. After the anvil plate 8640 is secured tothe anvil jaw portion 8630, the clampable member may be removed anddiscarded before the surgical stapling assembly 8600 is used. In atleast one instance, the deformable members are part of the anvil plate8630 and are configured to be secured to the anvil jaw portion 8630.

In at least one instance, an anvil cap is configured to be positioned ona distal end of the anvil jaw portion 8630. The anvil cap is configuredto secure the anvil plate 8640 to the anvil jaw portion 8630. In atleast one instance, the anvil plate 8640 is slid into the anvil jawportion 8630 and, without the anvil cap, can only be removed by pullingthe anvil plate 8640 distally from the distal end of the anvil jawportion 8630. Such an anvil cap can secure the anvil plate 8640 at thedistal end of the anvil jaw portion 8630. In at least one instance, thedistal end of the anvil jaw portion 8630 comprises threads and the anvilcap comprises corresponding threads configured to be threaded onto thethreads on the distal end of the anvil jaw portion 8630 to secure theanvil cap to the anvil jaw portion 8630. In at least one instance, theanvil cap comprises a polymer material. In at least one instance, theanvil cap is snapped onto the distal end of the anvil jaw portion 8630and unsnapped from the distal of anvil jaw portion 8630 to replace theanvil plate 8640. In various instances, a user can install and uninstallthe anvil cap. In other instances, a specific tool is required toinstall and/or uninstall the anvil cap from the anvil jaw portion 8630.In at least one instance, the specific tool is provided with thereplaceable anvil plate 8640 and/or replaceable staple cartridge 8620.As discussed above, a replaceable anvil plate and a replaceable staplecartridge can come as a single replaceable unit to be installed within asurgical stapling assembly. In various instances, a user can mix andmatch anvil plates and replaceable staple cartridges to tune the type ofstaple line, tissue compression, and/or gripping pressure, for example,desired fora particular use. This can be based on the targeted tissueand/or type of operation, for example. For example, the one or more rowsof forming pockets 8642 in certain anvil plates 8640 can include formingpockets having transverse pocket axes and configured to form 3D ornon-planar staples, as further described herein, while other rows offorming pockets 8642 include forming pockets having aligned pocket axesand configured to form 2D or planar staples. Additionally oralternatively, the anvil plate can include a stepped and/or contouredsurface to optimize the tissue gap for certain applications.

Various aspects of the subject matter described herein are set out inthe following examples.

Example Set 1

Example 1—A surgical stapling assembly comprising an anvil and a staplecartridge. The anvil comprises an anvil surface, a first row of formingpockets defined in the anvil surface, and a second row of formingpockets defined in the anvil surface. The staple cartridge comprises adeck surface, a longitudinal slot defining a first cartridge side and asecond cartridge side of the staple cartridge, and a first row of staplecavities defined in the deck surface of the first cartridge side,wherein the first row of staple cavities is positioned a first lateraldistance from the longitudinal slot. The staple cartridge furthercomprises a first row of tissue gripping features extending from thedeck surface, wherein the first row of tissue gripping features isaligned with the first row of staple cavities and the first row offorming pockets, and wherein the first row of tissue gripping featurescomprises a first profile, a second row of staple cavities defined inthe deck surface of the first cartridge side, wherein the second row ofstaple cavities is positioned a second lateral distance from thelongitudinal slot, wherein the second lateral distance is greater thanthe first lateral distance, and a second row of tissue gripping featuresextending from the deck surface, wherein the second row of tissuegripping features is aligned with the second row of staple cavities andthe second row of forming pockets, wherein the second row of tissuegripping features comprises a second profile, and wherein the secondprofile and the first profile are different geometries. The staplecartridge further comprises a plurality of staples removably storedwithin the first row of staple cavities and the second row of staplecavities, wherein the staples removably stored within the first row ofstaple cavities are configured to be formed into a planar stapleconfiguration by the first row of forming pockets, and wherein thestaples removably stored within second row of staple cavities areconfigured to be formed into a nonplanar staple configuration by thesecond row of forming pockets.

Example 2—The surgical stapling assembly of Example 1, wherein eachforming pocket of the first row of forming pockets defines alongitudinal pocket axis, and wherein the longitudinal pocket axes arealigned.

Example 3—The surgical stapling assembly of Example 2, wherein eachforming pocket of the second row of forming pockets defines a transversepocket axis, and wherein the transverse pocket axes are transverse tothe longitudinal pocket axes.

Example 4—The surgical stapling assembly of any one of Examples 1, 2,and 3, wherein the anvil further comprises a third row of formingpockets defined in the anvil surface, wherein the staple cartridgefurther comprises a third row of staple cavities defined in the decksurface of the first cartridge side, wherein the third row of staplecavities is positioned a third lateral distance from the longitudinalslot, and wherein the third lateral distance is less than the firstlateral distance and the second lateral distance.

Example 5—The surgical stapling assembly of any one of Examples 1, 2, 3,and 4, wherein at least one of the anvil and the staple cartridge ismovable to reposition the surgical stapling assembly in a clampedconfiguration, wherein a first tissue gap distance is defined betweenthe first row of staple cavities and the first row of forming pockets inthe clamped configuration, wherein a second tissue gap distance isdefined between the second row of staple cavities and the second row offorming pockets in the clamped configuration, and wherein the firsttissue gap distance and the second tissue gap distance are differentdistances.

Example 6—The surgical stapling assembly of any one of Examples 1, 2, 3,4, and 5, wherein the plurality of staples comprise wire staples.

Example 7—The surgical stapling assembly of Example 6, wherein theplurality of staples comprise a uniform unformed height.

Example 8—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, and 7, wherein at least one of the anvil and the staplecartridge is movable to reposition the surgical stapling assembly in aclamped configuration, wherein the staple cartridge further comprises aplurality of first staple drivers positioned within the first row ofstaple cavities and a plurality of second staple drivers positionedwithin the second row of staple cavities, wherein a first formingdistance is defined between the first row of forming pockets and thefirst staple drivers in the clamped configuration, wherein a secondforming distance is defined between the second row of forming pocketsand the second staple drivers in the clamped configuration, and whereinthe first forming distance and the second forming distance are differentforming distances.

Example 9—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, 7, and 8, wherein the deck surface comprises a laterally curvedprofile.

Example 10—A surgical stapling assembly comprising an anvil and a staplecartridge. The anvil comprises an anvil surface, a first row of formingpockets defined in the anvil surface, and a second row of formingpockets defined in the anvil surface. The staple cartridge comprises adeck surface comprising a first row of deck protrusions and a second rowof deck protrusions. The staple cartridge further comprises alongitudinal slot defining a first cartridge side and a second cartridgeside, a first row of staple cavities defined in the deck surface of thefirst cartridge side positioned a first lateral distance from thelongitudinal slot, wherein the first row of deck protrusions is alignedwith the first row of staple cavities, and a second row of staplecavities defined in the deck surface positioned a second distance fromthe longitudinal slot, wherein the second distance is greater than thefirst distance, wherein the second row of deck protrusions is alignedwith the second row of staple cavities. The staple cartridge furthercomprises a plurality of staples removably stored within the first rowof staple cavities and the second row of staple cavities, wherein thefirst row of forming pockets are configured to form the staplesremovably stored within the first row of staple cavities into a planarstaple configuration, and wherein the second row of forming pockets areconfigured to form the staples removably stored within second row ofstaple cavities into a nonplanar staple configuration.

Example 11—The surgical stapling assembly of Example 10, wherein thefirst profile comprises a first height, wherein the second profilecomprises a second height, and wherein the first height and the secondheight are different heights.

Example 12—The surgical stapling assembly of any one of Examples 10 and11, wherein each staple in the plurality of staples comprises a crown, aproximal leg extending from the crown, and a distal leg extending fromthe crown, wherein, in the planar staple configuration, the proximal legand the distal leg define a leg plane which is coplanar with the crown.

Example 13—The surgical stapling assembly of Example 12, wherein, in thenonplanar staple configuration, the proximal leg defines a proximal legplane and the distal leg defines a distal leg plane, and wherein theproximal leg plane is transverse to the distal leg plane.

Example 14—The surgical stapling assembly of any one of Examples 10, 11,12, and 13, wherein each staple of the plurality of staples comprisesthe same unformed height.

Example 15—The surgical stapling assembly of any one of Examples 10, 11,12, 13, and 14, wherein the deck surface comprises a laterally curvedprofile.

Example 16—The surgical stapling assembly of any one of Examples 10, 11,12, 13, 14, and 15, wherein the plurality of staples comprise wirestaples.

Example 17—The surgical stapling assembly of any one of Examples 10, 11,12, 13, 14, 15, and 16, wherein each forming pocket of the first row offorming pockets defines a longitudinal pocket axis, wherein thelongitudinal pocket axes are aligned, wherein each forming pocket of thesecond row of forming pockets defines a transverse pocket axis, andwherein the transverse pocket axes are transverse to the longitudinalpocket axes.

Example 18—A surgical stapling assembly comprising a shaft and an endeffector attached to the shaft. The end effector comprises an anvil anda staple cartridge. The anvil comprises an anvil surface, a first row offorming pockets defined in the anvil surface, and a second row offorming pockets defined in the anvil surface. The staple cartridgecomprises a deck surface, a longitudinal slot defining a first cartridgeside and a second cartridge side, and a first row of staple cavitiesdefined in the deck surface of the first cartridge side positioned afirst lateral distance from the longitudinal slot, wherein the decksurface comprises a plurality of first tissue gripping features alignedwith the first row of staple cavities. The staple cartridge furthercomprises a second row of staple cavities defined in the deck surface ofthe second cartridge side positioned a second distance from thelongitudinal slot, wherein the second distance is greater than the firstdistance, wherein each staple cavity of the second row of staplecavities comprises a plurality of second tissue gripping featuresaligned with the second row of staple cavities, wherein the first tissuegripping features and the second tissue gripping features definedifferent geometries, a plurality of first staples removably storedwithin the first row of staple cavities wherein the first row of formingpockets are configured to form the first staples into a planar stapleconfiguration with a formed height, and a plurality of second staplesremovably stored within the second row of staple cavities, wherein thesecond row of forming pockets are configured to form the second staplesinto a nonplanar staple configuration with the formed height.

Example 19—The surgical stapling assembly of Example 18, wherein eachforming pocket of the first row of forming pockets comprises a firstpocket depth and each forming pocket of the second row of formingpockets comprises a second pocket depth, and wherein the second pocketdepth is less than the first pocket depth.

Example 20—The surgical stapling assembly of Example 19, wherein a firstforming distance is defined by forming pockets of the first row offorming pockets and a second forming distance is defined by formingpockets of the second row of forming pockets, and wherein the firstforming distance and the second forming distance are different formingdistances.

Example 21—The surgical stapling assembly of any one of Examples 18, 19,and 20, wherein the staple cartridge further comprises a plurality offirst staple driver bodies configured to support the first staples,wherein a first forming distance is defined between the first stapledriver bodies and the forming pockets of the first row of formingpockets, and a plurality of second staple driver bodies configured tosupport the second staples, wherein a second forming distance is definedbetween the second staple driver bodies and the forming pockets of thesecond row of forming pockets.

Example 22—The surgical stapling assembly of Example 21, wherein thefirst forming distance and the second forming distance are differentforming distances.

Example 23—The surgical stapling assembly of any one of Examples 18, 19,20, 21, and 22, wherein the staple cartridge further comprises a sledcomprising a first rail configured to eject the first staples, whereinthe first rail comprises a first rail drive height, and a second railconfigured to eject the second staples, wherein the second railcomprises a second rail drive height, and wherein the first rail driveheight defines a first forming distance of the first staples and thesecond rail drive height defines a second forming distance of the secondstaples.

Example 24—The surgical stapling assembly of Example 23, wherein thefirst forming distance and the second forming distance are differentforming distances.

Example Set 2

Example 1—A surgical stapling assembly comprising a staple cartridgeassembly and a firing member assembly. The staple cartridge assemblycomprises a sled, a cartridge body comprising a plurality of staplecavities and a longitudinal slot, a longitudinal support beam positionedwithin the cartridge body, and a plurality of staples removably storedwithin the staple cavities. The firing member assembly is configured tomove through the staple cartridge assembly, wherein the firing memberassembly is configured to push the sled through a firing stroke to ejectthe staples from the cartridge body, and wherein the firing memberassembly comprises a first firing member comprising a first cammingflange positioned outside the cartridge body, and a second cammingflange configured to apply a camming force to the longitudinal supportbeam. The firing member assembly further comprises a second firingmember comprising a third camming flange positioned outside thecartridge body, and a fourth camming flange configured to apply acamming force to the longitudinal support beam.

Example 2—The surgical stapling assembly of Example 1, wherein thecartridge body comprises a first material, wherein the longitudinalsupport beam comprises a second material, and wherein the first materialand the second material are different materials.

Example 3—The surgical stapling assembly of any one of Examples 1 and 2,wherein the longitudinal support beam comprises a cylindrical cavityconfigured to receive a firing drive shaft therethrough during thefiring stroke.

Example 4—The surgical stapling assembly of Example 3, wherein the firstfiring member comprises a first cylindrical guide, wherein the secondfiring member comprises a second cylindrical guide, and wherein thefirst cylindrical guide and the second cylindrical guide are configuredto longitudinally translate within the cylindrical cavity.

Example 5—The surgical stapling assembly of any one of Examples 1, 2, 3,and 4, wherein the longitudinal support beam is positioned between thefirst camming flange and the third camming flange.

Example 6—The surgical stapling assembly of any one of Examples 1, 2, 3,4, and 5, wherein the first firing member is part of the staplecartridge assembly, wherein the staple cartridge assembly isreplaceable, and wherein the first firing member comprises a hookcouplable to the second firing member upon installation of the staplecartridge assembly in a cartridge channel.

Example 7—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, and 6, wherein the cartridge body further comprises lateralopposing walls and lateral support ledges extending from the laterallyopposing walls, and wherein the lateral support ledges are configured tobe received within corresponding lateral support slots defined in thelongitudinal support beam.

Example 8—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, and 7, wherein the second firing member is configured to pushthe first firing member.

Example 9—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, 7, and 8, wherein the longitudinal support beam comprises aproximal hook and a distal hook configured to be engaged with acartridge channel, and wherein the proximal hook and the distal hook areconfigured to longitudinally restrain the longitudinal support beamrelative to the cartridge channel.

Example 10—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, and 9, wherein the longitudinal support beam comprisesa first camming channel defined therein and configured to receive thesecond camming flange, and a second camming channel defined therein andconfigured to receive the fourth camming flange.

Example 11—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, 9, and 10, wherein the first firing member comprises aknife protruding out of the cartridge body.

Example 12—A replaceable staple cartridge configured to be installedinto a surgical stapling assembly, wherein the replaceable staplecartridge comprises a cartridge body comprising an internal longitudinalsupport channel, a plurality of staples removably stored within thecartridge body, and an internal longitudinal support positioned withinthe internal longitudinal support channel. The internal longitudinalsupport comprises a first camming channel defining a first upper limitand a first lower limit, a second camming channel defining a secondupper limit and a second lower limit, and a guide cavity configured toreceive a corresponding guide portion of a firing member assembly.

Example 13—The replaceable staple cartridge of Example 12, wherein theinternal longitudinal support is configured to transfer camming forcesapplied thereto to the cartridge body.

Example 14—The replaceable staple cartridge of any one of Examples 12and 13, wherein the guide cavity is configured to receive a flexiblefiring drive shaft therethrough during a firing stroke.

Example 15—The replaceable staple cartridge of any one of Examples 12,13, and 14, wherein the cartridge body further comprises a cartridgedeck and a cartridge bottom, and wherein the internal longitudinalsupport is positioned between the cartridge deck and the cartridgebottom.

Example 16—The replaceable staple cartridge of any one of Examples 12,13, 14, and 15, further comprising a firing member comprising a knifeand a hook couplable to a reusable portion of the firing member assemblyupon installation of the replaceable staple cartridge into the surgicalstapling assembly.

Example 17—A replaceable staple cartridge configured to be installedinto a cartridge channel of a surgical stapling assembly. Thereplaceable staple cartridge comprises a sled, a cutting membercomprising a knife and a camming portion, and a cartridge bodycomprising a cartridge deck, a plurality of staple cavities defined inthe cartridge deck, and a longitudinal support channel. The replaceablestaple cartridge further comprises a plurality of staples removablystored within the staple cavities, and a metal support body positionedwithin the longitudinal support channel. The metal support bodycomprises a first longitudinal cam channel configured to receive thecamming portion of the cutting member during a firing stroke, a secondlongitudinal cam channel substantially parallel to the firstlongitudinal cam channel, and a cylindrical guide cavity between thefirst longitudinal cam channel and the second longitudinal cam channel.

Example 18—The replaceable staple cartridge of Example 17, wherein thecylindrical guide cavity is configured to receive a flexible firingdrive shaft therethrough during the firing stroke.

Example 19—The replaceable staple cartridge of any one of Examples 17and 18, wherein the cartridge body further compriseslongitudinally-extending support ledges extending laterally inward fromopposing walls of the cartridge body, and wherein the support ledges areconfigured to be received within corresponding longitudinal supportslots defined in the metal support body.

Example 20—The replaceable staple cartridge of any one of Examples 17,18, and 19, wherein the cutting member further comprises a hookconfigured to releasable engage an instrument firing member in thesurgical stapling assembly upon installation of the replaceable staplecartridge into the surgical stapling assembly.

Example Set 3

Example 1—A surgical stapling assembly comprising a first jaw, a secondjaw movable relative to the first jaw, a firing screw, and a firingassembly configured to be actuated by the firing screw through a firingstroke. The firing assembly comprises a body portion and a nut. The bodyportion comprises a first cam configured to engage the first jaw duringthe firing stroke, a second cam configured to engage the second jawduring the firing stroke, a passage configured to non-threadably receivethe firing screw, and a driven surface. The nut is configured totransmit a drive force from the firing screw to the body portion duringthe firing stroke. The nut comprises a driven portion comprising apassage threadably coupled to the firing screw, wherein a clearance isdefined between the driven portion and the body portion, and a drivingportion extending from the driven portion, wherein the driving portionis configured to transmit the drive force to the driven surface offcenter from the firing screw during the firing stroke.

Example 2—The surgical stapling assembly of Example 1, wherein the driveforce is applied eccentrically with respect to a longitudinal axisdefined by the firing screw.

Example 3—The surgical stapling assembly of any one of Examples 1 and 2,wherein the clearance comprises a first longitudinal space situatedbetween a proximal end of the nut and the body portion, and wherein asecond longitudinal space is situated between a distal end of the nutand the body portion.

Example 4—The surgical stapling assembly of any one of Examples 1, 2,and 3, wherein one of the first jaw and the second jaw is configured toreceive a fastener cartridge comprising a plurality of fasteners.

Example 5—The surgical stapling assembly of any one of Examples 1, 2, 3,and 4, wherein the nut comprises a polymer material and the body portioncomprises a metallic material.

Example 6—The surgical stapling assembly of any one of Examples 1, 2, 3,4, and 5, wherein the nut is insert molded within the firing assembly.

Example 7—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, and 6, wherein the nut comprises an anti-rotation flangeconfigured to prevent the nut from rotating with the firing screw, andwherein the anti-rotation flange is engaged with one of the first jawand the second jaw.

Example 8—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, and 7, wherein the driven portion comprises a metallic nut,wherein the driving portion comprises a polymer, and wherein themetallic nut is insert molded within the driving portion.

Example 9—The surgical stapling assembly of Example 8, wherein themetallic nut comprises securement features configured to secure themetallic nut relative to the driving portion.

Example 10—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, and 9, wherein the nut comprises an internal crossbrace extending between a first side of the nut and a second side of thenut.

Example 11—The surgical stapling assembly of Example 10, wherein thebody portion of the firing assembly comprises a horizontally extendingslot configured to receive the internal cross brace.

Example 12—A surgical stapling assembly comprising a first jaw, a secondjaw movable relative to the first jaw, a drive screw defining alongitudinal axis, and a firing assembly configured to be actuated bythe drive screw through a firing stroke. The firing assembly comprises abody portion and a nut. The body portion comprises a first camconfigured to engage the first jaw during the firing stroke, a secondcam configured to engage the second jaw during the firing stroke, adrive screw passage dimensioned to receive the drive screw, anengagement portion, and a receptacle, wherein the engagement portionextends into the receptacle. The nut is installed in the receptacle,wherein the nut comprises a driven portion threadably coupled to thedrive screw, and a driving portion extending from the driven portion,wherein the driving portion comprises a brace mounted to the engagementportion, wherein the nut is configured to transfer a drive force to thebody portion at the brace and off center from the drive screw as the nutis moved distally and proximally by the drive screw.

Example 13—The surgical stapling assembly of Example 12, wherein thefiring assembly further comprises a clearance gap defined between thedriven portion and the body portion, and wherein the engagement portionis positioned above the clearance gap.

Example 14—The surgical stapling assembly of any one of Examples 12 and13, wherein the nut comprises a trapezoidal shape.

Example 15—The surgical stapling assembly of any one of Examples 12, 13,and 14, wherein the nut comprises a polymer material and the bodyportion comprises a metallic material.

Example 16—The surgical stapling assembly of any one of Examples 12, 13,14, and 15, wherein the nut is insert molded within the firing assembly.

Example 17—The surgical stapling assembly of any one of Examples 12, 13,14, 15, and 16, wherein the nut comprises an anti-rotation flangeconfigured to prevent the nut from rotating with the drive screw.

Example 18—The surgical stapling assembly of any one of Examples 12, 13,14, 15, 16, and 17, wherein the brace comprises a plurality ofcrossbars.

Example 19—A surgical end effector assembly comprising an anvil, astaple cartridge comprising a sled and a plurality of staples, a rotarydrive screw, and a firing member assembly configured to be actuated bythe rotary drive screw through a firing stroke to advance the sledthrough the staple cartridge along a longitudinal axis. The firingmember assembly comprises a distal head and a nut. The distal headcomprises a sled drive surface configured to push the sled distallywithin the staple cartridge, a drive member channel, wherein the rotarydrive screw is positioned within the drive member channel, a first drivesurface, and a cavity defined in the distal head along a cavity axisoriented transverse to the longitudinal axis, wherein the cavitycomprises a second drive surface. The nut comprises a driven portiondrivingly coupled to the rotary drive screw, and a driving portionextending from the driven portion. The driving portion comprises a firstdriving surface abutting the first drive surface, and a lateral crossmember extending into the cavity, wherein the lateral cross membercomprises a second driving surface abutting the second drive surface.

Example 20—The surgical end effector assembly of Example 19, wherein thenut is configured to apply an axial drive force to the distal headeccentrically with respect to the rotary drive screw.

Example 21—The surgical end effector assembly of any one of Examples 19and 20, wherein the firing member assembly further comprises a clearancegap defined between the driven portion and the distal head, and whereinthe first driven surface and the second driven surface are positionedabove the clearance gap.

Example 22—The surgical end effector assembly of any one of Examples 19,20, and 21, wherein the nut generally defines a trapezoidal shape.

Example 23—The surgical end effector assembly of any one of Examples 19,20, 21, and 22, wherein the nut is insert molded within the firingmember assembly.

Example 24—A surgical stapling assembly comprising a first jaw, a secondjaw movable relative to the first jaw, a rotary drive member configuredto rotate about a drive axis, and a firing assembly coupled to therotary drive member. The firing assembly comprises a body portioncomprising a first cam configured to engage the first jaw during afiring stroke, and a second cam configured to engage the second jawduring the firing stroke. The firing assembly further comprises a drivenportion drivingly coupled to the rotary drive member, and a drivingportion extending eccentrically from the driven portion, wherein thedriving portion is configured to transfer a drive force from the rotarydrive member to the body portion off axis with respect to the drive axisduring the firing stroke.

Example Set 4

Example 1—A surgical stapling assembly comprising an anvil, a cartridgechannel configured to receive a staple cartridge therein, and a firingassembly. The firing assembly comprises a firing member, a firing drivescrew, wherein the firing member is threadably coupled to the firingdrive screw, and wherein a rotation of the firing drive screw isconfigured to move the firing member longitudinally within the surgicalstapling assembly, and a mount configured to support the firing drivescrew within the cartridge channel, wherein the mount is configured topermit the firing drive screw to float within a limited vertical rangeof floatation relative to the cartridge channel.

Example 2—The surgical stapling assembly of Example 1, wherein the mountcomprises an upper stop and a lower stop defining the limited verticalrange of floatation of the firing drive screw between the upper stop andthe lower stop.

Example 3—The surgical stapling assembly of any one of Examples 1 and 2,wherein the firing member comprises an upper flange configured to engagethe anvil, and a lower flange configured to engage the cartridgechannel, wherein the upper flange and the lower flange define thelimited vertical range of floatation of the firing drive screw.

Example 4—The surgical stapling assembly of any one of Examples 1, 2,and 3, wherein the firing member comprises a drive nut cutout, andwherein the drive nut cutout defines the limited vertical range offloatation.

Example 5—The surgical stapling assembly of any one of Examples 1, 2, 3,and 4, wherein the cartridge channel comprises a proximal end portionand a distal end portion, wherein the firing drive screw is mountedwithin the cartridge channel at the proximal end portion and the distalend portion, and wherein the mount is positioned at the distal endportion.

Example 6—The surgical stapling assembly of Example 5, wherein the mountcomprises a first mount, wherein the cartridge channel further comprisesa second mount positioned at the proximal end portion, and wherein thesecond mount comprises a ball joint mount.

Example 7—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, and 6, further comprising a biasing member configured to bias thefiring drive screw toward a neutral position within the mount.

Example 8—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, and 7, wherein the mount comprises a recessed flange and aclip.

Example 9—The surgical stapling assembly of any one of Examples 1, 2, 3,4, 5, 6, 7, and 8, wherein the firing drive screw comprises a proximalend and a distal end, and wherein the distal end is swaged.

Example 10—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, and 9, further comprising the staple cartridgecomprising a plurality of staples.

Example 11—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, 9, and 10, wherein the limited vertical range offloatation comprises a range between about 0.0002 inches and about0.0003 inches.

Example 12—The surgical stapling assembly of any one of Examples 1, 2,3, 4, 5, 6, 7, 8, 9, 10, and 11, wherein the limited vertical range offloatation comprises a range of about 0.0001 inches.

Example 13—A surgical end effector assembly comprising a first jaw, asecond jaw movable relative to the first jaw, an anvil, a cartridgechannel configured to receive a staple cartridge therein, wherein thecartridge channel comprises a drive member support, and a firingassembly. The firing assembly comprises a firing member comprising anupper flange configured to engage the anvil, and a lower flangeconfigured to engage the cartridge channel. The firing assembly furthercomprises a rotary drive screw, wherein the firing member is threadablycoupled to the rotary drive screw such that a rotation of the rotarydrive screw is configured to move the firing member within the surgicalend effector assembly through a firing stroke, and wherein the drivemember support is configured to support the rotary drive screw andpermit the rotary drive screw to float vertically relative to the drivemember support as the firing member is advanced through the firingstroke.

Example 14—The surgical end effector assembly of Example 13, wherein thedrive member support comprises an upper stop and a lower stop defining alimited vertical range of floatation of the rotary drive screw betweenthe upper stop and the lower stop.

Example 15—The surgical end effector assembly of any one of Examples 13and 14, wherein the upper flange and the lower flange define a limitedvertical range of floatation.

Example 16—The surgical end effector assembly of any one of Examples 13,14, and 15, wherein the cartridge channel comprises a proximal endportion and a distal end portion, wherein the rotary drive screw issupported by the cartridge channel at the proximal end portion and thedistal end portion, and wherein the drive member support is positionedat the distal end portion.

Example 17—The surgical end effector assembly of Example 16, wherein thedrive member support comprises a first drive member support, wherein thesurgical end effector assembly further comprises a second drive membersupport positioned at the proximal end portion, wherein the rotary drivescrew comprises a proximal mount end, and wherein the proximal mount endcomprises a ball joint portion mounted within the second drive membersupport.

Example 18—The surgical end effector assembly of any one of Examples 13,14, 15, 16, and 17, further comprising a biasing member configured tobias the rotary drive screw toward a neutral position within the drivemember support.

Example 19—The surgical end effector assembly of any one of Examples 13,14, 15, 16, 17, and 18, wherein the drive member support comprises arecessed flange and a clip.

Example 20—The surgical end effector assembly of any one of Examples 13,14, 15, 16, 17, 18, and 19, further comprising the staple cartridgecomprising a plurality of staples.

Example 21—A surgical stapling assembly comprising a shaft and an endeffector. The end effector comprises a first jaw, a second jaw movablerelative to the first jaw, an anvil, a cartridge channel, and a firingassembly. The firing assembly comprises a firing drive screw and afiring member comprising a drive nut threadably coupled to the firingdrive screw, wherein a rotary actuation of the firing drive screw isconfigured to move the firing member longitudinally within the endeffector through a firing stroke, and wherein the drive nut isconfigured to float relative to the firing member during the firingstroke.

Example 22—The surgical stapling assembly of Example 21, wherein thedrive nut is configured to float relative to the firing member laterallyand vertically with respect to the firing stroke.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The Entire Disclosures of:

U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,which issued on Apr. 4, 1995;

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21,2006;

U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued onSep. 9, 2008;

U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL INSTRUMENTWITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which issued on Dec.16, 2008;

U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;

U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, whichissued on Jul. 13, 2010;

U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE, which issued on Mar. 12, 2013;

U.S. patent application Ser. No. 11/343,803, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat. No. 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled SURGICAL CUTTINGAND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008;

U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009, now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLINGINSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012,now U.S. Pat. No. 9,101,358;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat.No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. patentapplication Publication No. 2014/0263552;

U.S. patent application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. patent application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one or moreother embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical stapling assembly, comprising: a firstjaw; and a second jaw movable relative to said first jaw; a firingscrew; and a firing assembly configured to be actuated by said firingscrew through a firing stroke, wherein said firing assembly comprises: abody portion, comprising: a first cam configured to engage said firstjaw during the firing stroke; a second cam configured to engage saidsecond jaw during the firing stroke; a passage configured tonon-threadably receive said firing screw; and a driven surface; and anut configured to transmit a drive force from said firing screw to saidbody portion during the firing stroke, wherein said nut comprises: adriven portion comprising a passage threadably coupled to said firingscrew, wherein a clearance is defined between said driven portion andsaid body portion; and a driving portion extending from said drivenportion, wherein said driving portion is configured to transmit thedrive force to said driven surface off center from said firing screwduring the firing stroke.
 2. The surgical stapling assembly of claim 1,wherein said drive force is applied eccentrically with respect to alongitudinal axis defined by said firing screw.
 3. The surgical staplingassembly of claim 1, wherein said clearance comprises a firstlongitudinal space situated between a proximal end of said nut and saidbody portion, and wherein a second longitudinal space is situatedbetween a distal end of said nut and said body portion.
 4. The surgicalstapling assembly of claim 1, wherein one of said first jaw and saidsecond jaw is configured to receive a fastener cartridge comprising aplurality of fasteners.
 5. The surgical stapling assembly of claim 1,wherein said nut comprises a polymer material and said body portioncomprises a metallic material.
 6. The surgical stapling assembly ofclaim 1, wherein said nut is insert molded within said firing assembly.7. The surgical stapling assembly of claim 1, wherein said nut comprisesan anti-rotation flange configured to prevent said nut from rotatingwith said firing screw, and wherein said anti-rotation flange is engagedwith one of said first jaw and said second jaw.
 8. The surgical staplingassembly of claim 1, wherein said driven portion comprises a metallicnut, wherein said driving portion comprises a polymer, and wherein saidmetallic nut is insert molded within said driving portion.
 9. Thesurgical stapling assembly of claim 8, wherein said metallic nutcomprises securement features configured to secure said metallic nutrelative to said driving portion.
 10. The surgical stapling assembly ofclaim 1, wherein said nut comprises an internal cross brace extendingbetween a first side of said nut and a second side of said nut.
 11. Thesurgical stapling assembly of claim 10, wherein said body portion ofsaid firing assembly comprises a horizontally extending slot configuredto receive said internal cross brace.
 12. A surgical stapling assembly,comprising: a first jaw; a second jaw movable relative to said firstjaw; a drive screw defining a longitudinal axis; and a firing assemblyconfigured to be actuated by said drive screw through a firing stroke,wherein said firing assembly comprises: a body portion, comprising: afirst cam configured to engage said first jaw during the firing stroke;a second cam configured to engage said second jaw during the firingstroke; a drive screw passage dimensioned to receive said drive screw;an engagement portion; and a receptacle, wherein said engagement portionextends into said receptacle; and a nut installed in said receptacle,wherein said nut comprises: a driven portion threadably coupled to saiddrive screw; and a driving portion extending from said driven portion,wherein said driving portion comprises a brace mounted to saidengagement portion, wherein said nut is configured to transfer a driveforce to said body portion at said brace and off center from said drivescrew as said nut is moved distally and proximally by said drive screw.13. The surgical stapling assembly of claim 12, wherein said firingassembly further comprises a clearance gap defined between said drivenportion and said body portion, and wherein said engagement portion ispositioned above said clearance gap.
 14. The surgical stapling assemblyof claim 12, wherein said nut comprises a trapezoidal shape.
 15. Thesurgical stapling assembly of claim 12, wherein said nut comprises apolymer material and said body portion comprises a metallic material.16. The surgical stapling assembly of claim 12, wherein said nut isinsert molded within said firing assembly.
 17. The surgical staplingassembly of claim 12, wherein said nut comprises an anti-rotation flangeconfigured to prevent said nut from rotating with said drive screw. 18.The surgical stapling assembly of claim 12, wherein said brace comprisesa plurality of crossbars.
 19. A surgical end effector assembly,comprising: an anvil; a staple cartridge comprising a sled and aplurality of staples; a rotary drive screw; and a firing member assemblyconfigured to be actuated by said rotary drive screw through a firingstroke to advance said sled through said staple cartridge along alongitudinal axis, wherein said firing member assembly comprises: adistal head, comprising: a sled drive surface configured to push saidsled distally within said staple cartridge; a drive member channel,wherein said rotary drive screw is positioned within said drive memberchannel; a first drive surface; and a cavity defined in said distal headalong a cavity axis oriented transverse to the longitudinal axis,wherein said cavity comprises a second drive surface; and a nut,comprising: a driven portion drivingly coupled to said rotary drivescrew; and a driving portion extending from said driven portion, whereinsaid driving portion comprises: a first driving surface abutting saidfirst drive surface; and a lateral cross member extending into saidcavity, wherein said lateral cross member comprises a second drivingsurface abutting said second drive surface.
 20. The surgical endeffector assembly of claim 19, wherein said nut is configured to applyan axial drive force to said distal head eccentrically with respect tosaid rotary drive screw.
 21. The surgical end effector assembly of claim19, wherein said firing member assembly further comprises a clearancegap defined between said driven portion and said distal head, andwherein said first driven surface and said second driven surface arepositioned above said clearance gap.
 22. The surgical end effectorassembly of claim 19, wherein said nut generally defines a trapezoidalshape.
 23. The surgical end effector assembly of claim 19, wherein saidnut is insert molded within said firing member assembly.
 24. A surgicalstapling assembly, comprising: a first jaw; a second jaw movablerelative to said first jaw; a rotary drive member configured to rotateabout a drive axis; and a firing assembly coupled to said rotary drivemember, wherein said firing assembly comprises: a body portion,comprising: a first cam configured to engage said first jaw during afiring stroke; and a second cam configured to engage said second jawduring the firing stroke; a driven portion drivingly coupled to saidrotary drive member; and a driving portion extending eccentrically fromsaid driven portion, wherein said driving portion is configured totransfer a drive force from said rotary drive member to said bodyportion off axis with respect to said drive axis during the firingstroke.